Manual Transmission (MUA Models) PDF

WORKSHOP MANUAL
TF SERIES
MANUAL TRANSMISSION
(MUA MODELS)
SECTION 7B1
MANUAL TRANSMISSION 7B1-1
SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
2)
MUA (4
Service Precaution .......................................................................................................... 7B1 3
General Description ........................................................................................................ 7B1 4
2) ........................................................................................................... 7B1 5
Rear Oil Seal (4
2) ......................................................................................................... 7B1 7
Transmission (4
Disassembled View..................................................................................................... 7B1 7
Removal ....................................................................................................................... 7B1 8
Installation ................................................................................................................... 7B1 12
Transmission Case .......................................................................................................... 7B1 18
Major Component ........................................................................................................ 7B1 18
Disassembly ................................................................................................................ 7B1 19
Reassembly ................................................................................................................. 7B1 20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 23
Disassembly ................................................................................................................ 7B1 24
Inspection and Repair................................................................................................. 7B1 25
Reassembly ................................................................................................................. 7B1 26
Reverse Gear and 5th Gear ............................................................................................ 7B1 27
Disassembly ................................................................................................................ 7B1 29
Reassembly ................................................................................................................. 7B1 31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 38
Disassembly ................................................................................................................ 7B1 40
Reassembly ................................................................................................................. 7B1 45
Main Data and Specifications ......................................................................................... 7B1 51
7B1-2 MANUAL TRANSMISSION
Troubleshooting............................................................................................................... 7B1 55
2) .......................................................................................................... 7B1 62
Special Tools (4
4)
MUA (4
Service Precaution .......................................................................................................... 7B1 63
General Description ........................................................................................................ 7B1 64
4) ......................................................................................................... 7B1 65
Transmission (4
Removal ....................................................................................................................... 7B1 66
Installation ................................................................................................................... 7B1 70
Transmission Case .......................................................................................................... 7B1 77
Major Component ........................................................................................................ 7B1 77
Disassembly ................................................................................................................ 7B1 78
Reassembly ................................................................................................................. 7B1 79
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 82
Disassembly ................................................................................................................ 7B1 83
Reassembly ................................................................................................................. 7B1 84
Reverse Gear and 5th Gear ............................................................................................ 7B1 85
Disassembly ................................................................................................................ 7B1 86
Reassembly ................................................................................................................. 7B1 88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 94
Disassembly ................................................................................................................ 7B1 96
Inspection and Repair.............................................................................................. 7B1 98
Reassembly .............................................................................................................. 7B1 101
Main Data and Specifications ..................................................................................... 7B1 107
Troubleshooting ........................................................................................................... 7B1 111
4) ...................................................................................................... 7B1 118
Special Tools (4
Service Precaution CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use
ONLY the exact part number for that application.
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
ISUZU will call out those fasteners that require a
RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out
COMPONENT AND WIRING LOCATION VIEW IN the fasteners that require thread lockers or thread
ORDER TO DETERMINE WHETHER YOU ARE sealant. UNLESS OTHERWISE SPECIFIED, do not
PERFORMING SERVICE ON OR NEAR THE SRS use supplemental coatings (Paints, greases, or
COMPONENTS OR THE SRS WIRING. WHEN YOU other corrosion inhibitors) on threaded fasteners or
ARE PERFORMING SERVICE ON OR NEAR THE fastener joint interfaces. Generally, such coatings
SRS COMPONENTS OR THE SRS WIRING, REFER adversely affect the fastener torque and the joint
TO THE SRS SERVICE INFORMATION. FAILURE TO clamping force, and may damage the fastener.
When you install fasteners, use the correct
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
tightening sequence and specifications. Following
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR these instructions can help you avoid damage to
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. parts and systems.
General Description
2)
MUA Transmission (4
A07R300006
The MUA is a constant mesh transmission, Principle parts of the transmission are the integral clutch
synchronized in all speeds. The transmission has been housing, the intermediate plate, the rear cover, and the
designed to provide low shift effort and low gear noise. gears.
The transmission control box is built into the
transmission.
2)
Rear Oil Seal (4
Disassembled View
220R300030
Legend
(1) Rear Propeller Shaft (2) Rear Oil Seal
Removal
1. Raise and support vehicle with suitable jack stands.
2. Remove propeller shaft flange yoke bolts and nuts
at the differential side.
3. Remove center bearing from crossmenber.
4. Remove prepeller shaft from the transmission main
shaft spline.
Refre to the section Rear Propeller Shaft.
5. Use a screwdriver to pry the rear oil seal from the
rear cover.
Installation
1. Install a new oil seal (2) using the installer 5-8522-
0050-0.
220RS044
2. Insert the splined yoke into the transimission

mainshaft spline.
3. Install the propeller shaft flange yoke to the drive
pinion flange.
Torque : 63 Nm (6.4 kgm/46 lbft)

4. Install center bearing on crossmember.
Torque : 69 Nm (7.0 kgm/51 lbft)
5. Check transmission fluid level.
6. Lower vehicle.
2)
Transmission (4
Disassembled View
RTW47BLF000701
Legend
(1) Gear Control Lever Knob (10) Slave Cylinder
(2) Rear Floor Console (bucket seat) (11) Nut : rear mount to Crossmember
(3) Front Floor Console (12) Transmission Crossmember
(4) Grommet Assembly (13) Nut : rear mount to transmission
(5) Gear Control Lever (14) Rear Mount Rubber
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe (6VE1 only) (17) Transmission Assembly
(9) Fuel Pipe Bracket
Removal 5. Remove grommet assembly (4).

1. Disconnect battery ground cable.
2. Remove gear control lever knob (1).
3. Remove rear floor console (2). (Bucket seat)
Refer to the section Floor Console.
4. Remove front floor console (3).
745R300006
Legend RTW47BMH000101
(1) Knob
(2) Rear Floor Console
(3) Front Floor Console
6. Remove gear control lever (5). 10. Remove the exhaust pipe (8). (6VE1 only)
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.
RTW37ASH0001
11. Disconnect harness connectors and clips on the

transmission.
Neutral Switch
Back up Switch
401RS023 Car Speed Sensor
9. Loosen the front exhaust pipe fixing nuts (7) at the
12. Remove the fuel pipe bracket (9) with pipes from the
engine side but not remove them. (Diesel engine
transmission (17).
only)
Diesel engine
220R300012
150R300003
Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
14. Support transmission with a transmission jack.

6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it. 220RS001
15. Remove engine rear mount nuts (11) fixing on cross

Diesel engine member from transmission crossmember (12).
16. Remove engine rear mount nuts (13) fixing on
transmission.
220LV019
6VE1
220R300029
Legend
(1) Transmission
(2) Nut : rear mount to transmission
(3) Rear Mount Rubber
(4) Nut : rear mount to crossmember
(5) Transmission Crossmember
206RW002
17. Remove the middle part of transmission 20. Use the clutch release bearing remover 5-8840-
crossmember (12) by removing four fixing bolts and 2291-0 (J-39207) to disconnect the clutch release
nuts. bearing from the clutch pressure plate. (6VE1 only)
501R300008 220RW109
18. Take out the rear mount rubber (14). Release bearing disconnection
19. Remove starter (15) (Diesel engine only). 1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.
060L100070
NOTE: Be sure not to insert the remover between the

wedge collar and the clutch.
220RW019
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
21. Remove transmission retaining nuts and bolts(16).

Remove transmission assembly (17) from the
vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
220RW063 the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
220RW064
4. Install the transmission assembly (17) to the engine.

Tighten the transmission nuts and bolts (16) as
shown in the figure.
Diesel engine
RTW37BLF000901
6VE1
RTW37BLF0001
C24NE
RTW37BLF0002
5. Apply a force of about 113N (26 Ib) to the tip of the

shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.
220RS006
6. Install starter(15). (Diesel engine only)

6VE1, C24NE
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N m (7.7 kg m/56 lb
ft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
ft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N m (6.8 kg
m/49 lbft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).
Torque: 52 Nm (5.3 kg
m/38 lbft) Scan-1
Remove the transmission jack from transmission 12. Connect transmission harness connectors and clip.
side. Connector: neutral switch, car speed sensor, and
10. Apply grease to top hole portion of the shift fork. backup switch.
Install slave cylinder (10) and tighten the bolts to the 13. Tighten exhaust pipe fixing nuts (7) to the specified
specified torque. torque. (Diesel engine only)
Torque: 76 N m (7.7 kgm/56 lbft) m (6.8 kg
Torque: 67 N m/49 lb
ft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut m (7.7 kg
76 N m/56 lb
ft)
Nut m (3.8 kg
37 N m/28 lb
ft)
Diesel engine
150R300003
220R300012
Legend
(1) Bolt
(2) Nut
14. Install the exhaust pipe (8). (6VE1)

m (6.8 kg
ft)
RTW37ASH000101
15. Install rear propeller shaft (6).

Torque: 63 N m (6.4 kgm/46 lb
ft)
16. Install center bearing on crossemember.
ft)
RTW47BMH000101
17. Install gear control lever (5). Legend
m/14 lb
ft) (1) Grommet Assembly
18. Install grommet assembly (4). (2) Floor Panel
Torque: Screw m (0.14 kg
1.4 N m/12 lb
in) (3) Front
Nut m (0.7 kg
7 N m/61 lb
in)
19. Install front floor console (3) and rear floor console
(2).
20. Install gear control lever knob (1).
To the female thread portion, adhesive (TB1344 or
LOCTITE 222 or equiv.) of 3 - 4 drops to be applied
and transmission knob tightened.
Torque: 9 N m (0.9 kgm/78 lb in)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
21. Connect battery ground cable.
Transmission Case
Major Component
RTW37BLF0005
Legend
(1) Gear Control Box Assembly and Gasket (9) Front Cover (with Oil Seal)
(2) Speedometer Sensor and Driven Gear (10) Top Gear Bearing Snap Ring
(3) Rear Cover Assembly (11) Release Bearing : C24NE
(4) Intermediate Plate with Gear Assembly (12) Shift Fork : C24NE
(5) Transmission Case (13) Fulcrum Bridge : 6VE1
(6) Release Bearing (with Spring) : Diesel engine (14) Release Bearing : 6VE1
(7) Shift Fork : Diesel engine (15) Shift Fork : 6VE1
(8) Counter Front Bearing Snap Ring
Disassembly 7. Remove the fulcrum bridge from the transmission

1. Clean the exterior of the unit with solvent. case. (6VE1)
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring
(6)(11) from the transmission case.
4. Remove the shift fork (7)(12), and boot. (Diesel
engine, C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)
RTW37ASH0002
Legend
(1) Fulcrum bridge
8. Remove the front cover (9) and gasket from the
transmission case.
9. Remove snap ring (8) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (10) fixing top gear bearing.
RTW47BSH000601
Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
226RS001
11. Remove the speedometer sensor (2).

Remove the plate (2).
Remove the driven gear bushing and driven gear
(2).
NOTE : Apply a reference mark to the driven gear
bushing before removal.
12. Remove gear control box assembly (1).
13. Remove the rear cover assembly (3) from the 4. Install a new gasket and gear control box assembly
transmission case (5) and intermediate plate (4). (1).
14. Remove intermediate plate with gear assembly (4) Install the harness clips and brackets and then
from transmission case (5). tighten four new gear control box bolts to the
Reassembly specified torque.
1. Apply recommended liquid gasket (LOCTITE 17430) m (2.0 kg
ft)
or its equivalent to the transmission case (5),
intermediate plate (4) and rear cover (3) fitting
surfaces.
2. Install the intermediate plate with gear assembly (4)
to the transmission case (5).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the main shaft to sudden shock or
stress.
3. Install the rear cover with oil seal (3) on the
intermediate plate with gear (4) by performing the
following steps.
Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
261R300004
5. Install the O-ring (4) to the speedometer driven gear

bushing (3).
Install the driven gear to the speedometer driven
gear bushing (3).
6. Install the speedometer driven gear assembly (2) to
the transmission rear cover (3).
Install the plate (1) to the transmission rear cover
(3).
m (1.5 kg
ft)
7. Install the speedometer sensor (2). Use the oil seal installer 5-8840-0026-0 to install
m (2.8 kg
ft) the oil seal to the front cover.
220R3000020
10. Install a new gasket and front cover (9) to the

transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
After cleaning the bolt hole, dry it thoroughly with air.
After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
liquid gasket (LOCTITE 242) or its equivalent before
225R300001 tightening it.
8. Install top gear bearing snap ring (10) and counter Tighten six front cover bolts to the specified torque.
front bearing snap ring (8).
Use a pair of snap ring pliers to install the snap Torque: 25 N m (2.6 kgm/19 lbft)
rings to the mainshaft and countershaft. 11. Apply molybdenum disulfide type grease to the
The snap rings must be fully inserted into the areas as shown in the figure and install shift fork (7).
bearing snap ring groove. (Diesel engine, C24NE)
9. Front cover with oil seal (9).
Front Cover Oil Seal Replacement
Remove the oil seal from the front cover.
Apply engine oil to a new oil seal outer
circumference.
Apply recommended grease to the oil seal lip.
F07L100026
12. Install the fulcrum bridge to the transmission case. 15. Install the washer and snap pin. (6VE1)
(6VE1)
m (3.9 kg
ft)
RTW37ASH0002
Legend
(1) Fulcrum bridge
13. Apply molybdenum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
(6VE1) RTW47BMH000201
14. Attach the shift fork to the fulcrum bridge and insert 16. Pack the inside recess (A) and coat the back (B) of
the pin from below of the fulcrum bridge. (6VE1) the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
17. Install the release bearing (6) on the front cover,

joining it to the shift frok.
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View
RTW47BLF000501
Legend
(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly
Disassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent balls
from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when

pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.
220RS011
2. Remove spring (4).

3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).
Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift

rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.
Inspection and Repair

Make the necessary adjustments, and part
replacements if excessive wear or damage is
discovered during inspection.
Shift Arm Thickness
Use a micrometer to measure the shift arm
thickness.
If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift Arm Thickness
Standard Limit
9.60 - 9.85 mm
1st-2nd
(0.378 - 0.388 in) 9.0 mm
3rd-4th 9.60 - 9.80 mm (0.354 in)
Rev.5th (0.378 - 0.386 in)
220RS012
Detent Spring Tension

Use a spring tester to measure the detent spring
tension.
the detent spring must be replaced.
Compressed height Standard
87.2 - 97.1 N
20 mm (0.787 in)
(19.6 - 21.8 lb)
230RS006
Detent Spring Free Length

Use a vernier caliper to measure the detent spring
free length.
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)
220RS013
SOUTH AFRICA 5th-Rev Only SOUTH AFRICA 5th-RV Only

Detent Spring Free Length Detent Spring Free Length
Standard Limit Compressed Standard
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in) 93.5 103.3 N
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in) Outer 20 mm (0.787 in)
(21.0 23.3 lb)
26.4 36.3 N
Inner 20 mm (0.787 in)
(5.9 8.2 lb)
Reassembly 4. Install spring (4).

1. Install rev-5th shift arm and reverse inhibitor (6) and 5. Put detent balls (3) in the intermediate plate holes.
rev-5th shift rod (5). Apply oil to the detent balls.
Apply oil to the reverse inhibitor inner surface. 6. Install detent springs (2) and detent spring plate and
Install the shift rod in the intermediate plate (12). gasket (1).
Hold a round bar against the shift rod end lower Install a new gasket and the detent spring plate.
face to protect it against damage. Tighten the detent spring plate bolts to the
Install a new spring pin. specified torque.
Never reinstall the used spring pin. m (2.5 kg
ft)
Install the interlock pin (11) in the intermediate
plate (12).
Do not allow the interlock pin to fall from the
intermediate plate (12).
2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9)
to intermediate plate and gear assembly (12).
3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).
plate and gear assembly (12).
Install the 3rd-4th shift rod (8) in the intermediate
plate (12).
intermediate plate.
Install the interlock pin (11) and then 1st-2nd
shift rod (7) in the intermediate plate (12).
intermediate plate.
Hold a round bar against the shift rod end lower 220RS030
face to protect it against damage. Legend

Install a new spring pin. (1) Warped
Never reinstall the used spring pin.
230RS007
Reverse Gear and 5th Gear

Disassembled View
226R300027
Legend
(1) Bearing Snap Ring (11) Reverse Idler Gear Assembly
(2) Ball Bearing (12) Idle Shaft Pin
(3) Bearing Snap Ring (13) Thrust Washer
(4) Speedometer Drive Gear (14) Reverse Idler Gear
(5) Clip (15) Reverse Idler Shaft
(6) Retainer Snap Ring (16) Bearing Snap Ring
(7) Retainer (17) Ball Bearing
(8) Thrust Plate (18) Counter 5th Gear
(9) Thrust Washer and Lock Ball (19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring (20) 5th Gear
(21) 5th Block Ring (26) Reverse Gear

(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate
Disassembly 6. Remove the reverse idler gear assembly (11) from

1. Use a pair of snap ring pliers to remove the bearing the intermediate plate (30).
snap ring (1).
2. Set the bearing remover 5-8840-2155-0 and puller
5-8840-2027-0 to the bearing (2) and the mainshaft
end to remove the ball bearing (2).
226RS005
7. Remove idle shaft pin (12), thrust washer (13),

reverse idler gear (14), and reverse idler shaft (15).
262L100001
ring (16).
3. Remove the bearing snap ring (3), clip (5), 9. Attach a universal puller to the counter gear shaft.
speedometer drive gear (4), retainer snap ring (6) Use a universal puller to remove the ball bearing
and retainer (7). (17) and the counter 5th gear (18).
4. Remove thrust plate (8) and thrust washer and lock
ball (9).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (10).
226RS006
10. Remove counter reverse gear (19).
226RS004
11. Remove 5th gear (20), 5th block ring (21), and
needle bearing (2 piece type) (22).
226RW210
Use the mainshaft nut wrench 5-8840-2156-0 to

226RS007 remove the mainshaft nut (23).
12. Remove the mainshaft nut (23) according to
following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd

gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
13. Use screw drivers between the reverse gear (26)

and bearing plate (28) to remove the Rev-5th
synchronizer assembly (24) together with reverse
block ring (25) and reverse gear (26).
226RS011
17. Hold the snap ring open with the pliers.

Push the intermediate plate (30) toward the rear of
the transmission to remove it.
226RS010
The bearing snap ring (29) will come free.
14. Remove needle bearing (27).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(28) from the Inspection and Repair
intermediate plate. Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (30) on the gear
assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).
226RW212
2. Install bearing snap ring (29). 5. Assemble rev-5th synchronizer assembly (24) by
3. Apply recommended thread locking agents performing the following steps.
(LOCTITE 242) or its equivalent to each of the 1. Turn the clutch hub face (1) toward the sleeve
bearing plate screw threads. groove (2) (rear side) on the outer
Install bearing plate and screw (28). circumference.
Tighten the screws to the specified torque by using 2. Check that the inserts (3) fit snugly into the
torx bit wrench 5-8840-0047-0. clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
m (1.5 kg
ft) the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (24) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.
220RW137
4. Install needle bearing (27), reverse gear (26), and

reverse block ring (25).
226RS013
226RS049
6. Mesh the 1st-2nd and 3rd-4th synchronizers with 8. Use a punch to stake the mainshaft nut (23).
both the 1st and 3rd gears (double engagement).
226RW153
226RS015 9. Install needle bearing (22), 5th block ring (21), and
This will prevent the mainshaft from turning. 5th gear (20).
7. Install the new mainshaft hub nut. 10. Apply engine oil to the counter reverse gear (19) and
Use the mainshaft nut wrench 5-8840-2156-0 to the reverse gear (26).
tighten the mainshaft nut (23) to the specified Install the counter reverse gear (19) to the counter
torque. shaft.
m (14 kg
ft) The reverse gear projection must be facing the
intermediate plate.
226RW214
226RW151
11. Install the counter 5th gear (18) to the counter shaft. There are six snap ring sizes available.
The snap rings are color&dash;coded to indicate
their thickness.
226RS019
12. Install ball bearing (17) and bearing snap ring (16)
by performing the following steps: 226RS021
Select the snap ring which will provide the Ball Bearing and Snap Ring Clearance
minimum clearance between the ball bearing Standard: 0 - 0.15 mm (0 - 0.0059 in)
and the snap ring.
Snap Ring Availability
Thickness Color Coding
1.1 mm (0.043 in) White
1.2 mm (0.047 in) Yellow
1.3 mm (0.051 in) Blue
1.4 mm (0.055 in) Pink
1.5 mm (0.059 in) Green
1.6 mm (0.063 in) Brown
Use a pair of snap ring pliers to install the snap

ring(13) to the counter gear shaft.
The snap ring must be fully inserted into the
counter gear shaft snap ring groove.
13. Assemble reverse idler shaft (15), reverse idler gear
(14), thrust washer (13), and idle shaft pin (12) into
reverse idler gear assembly (11).
The trust washer should be assembled as oil groove
226RS020
faces to gear side.
14. Select reverse idler gear snap ring (10) which will Use a pair of snap ring pliers to install the snap
provide the minimum clearance between the ring to the reverse idler shaft.
intermediate plate (30) and the snap ring (10). The snap ring must be fully inserted into the
reverse idler shaft snap ring groove.
15. Install thrust washer and lock ball (9) by performing
the following steps:
Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in))
Measure clearance "A" as shown in the figure.
226RS022
There are three snap ring sizes available.

The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
1.2 mm (0.047 in) White
1.3 mm (0.051 in) Yellow 226RS023
Select appropriate thrust washer from chart.

1.4 mm (0.055 in) Blue
There are four thrust washer sizes available.
Thrust Washer Availability
Thickness Color Clearance
A mm (in)
mm (in) Coding mm (in)
8.05 - 8.1 0.15 - 0.25
7.9 (0.311) White
(0.317-0.319) (0.006-0.010)
8.1 - 8.2 0.1 - 0.25
8.0 (0.315) Yellow
(0.319-0.323) (0.004-0.010)
8.2 - 8.3 0.1 - 0.25
8.1 (0.319) Green
(0.323-0.327) (0.004-0.010)
8.3 - 8.36 0.1 - 0.21
8.2 (0.323) Blue
(0.327-0.329) (0.004-0.008)
The thrust washers are color coded to indicate

their thickness as shown in the figure.
226RS021
19. Install the bearing snap ring (1).
226RS024
Apply grease to the thrust washer and the lock

ball.
Install the thrust washer and the lock ball.
16. Install thrust plate (8) and retainer (7).
17. Install the retainer snap ring (6), clip (5),
speedometer drive gear (4) and bearing snap ring
(3).
18. Apply engine oil to the bearing (2) inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing (2) to the mainshaft.
226L100002
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
Legend
(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring
(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft
Disassembly 6. Use a bench press and the bearing remover 5-8840-

1. Use a pair of snap ring pliers to remove the top gear 0015-0 to remove the 3rd-4th synchronizer
shaft snap ring(1). assembly (7) as a set.
2. Remove top gear shaft(2) with ball bearing(3). Disassemble the synchronizer assembly.
3. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the ball bearing(3).
226RW217
Legend
226RW216
(1) Springs
4. Remove needle bearing (4) and top block ring (5), (2) Sleeve
mainshaft snap ring. (3) Clutch Hub
5. Use a pair of snap ring pliers to remove the (4) Inserts
mainshaft snap ring (6).
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RS008
226RW218
9.Disassemble 1st inside ring (15), 1st outside ring (16), 13. Remove needle bearing (25) from mainshaft (26).
and 1st block ring (17). 14. Remove bearing snap ring (27).
10.Remove needle bearing (18). 15. Remove the front roller bearing (28) by performing
11.Use a pair of snap ring pliers to remove the clutch the following steps.
hub snap ring (19).
Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.
Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RS031
12.Use bench press and the bearing remover 5-8840-

0015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
Disassemble the synchronizer assembly. 226RW219
16. Remove center roller bearing (29) from counter gear

shaft (30).
226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

Make the necessary adjustments, repairs, and part
Block Ring and Dog Teeth Clearance
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
226RS035
If the measured value exceeds the specified limit,

the block ring must be replaced.
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
1st-2nd Synchronizer (3-CONE) Block and Insert Clearance

Use a thickness gauge to measure the clearance Standard Limit
between the block ring and the dog teeth. 3.46 - 3.76 mm 4.0 mm
3rd-4th
(0.136 - 0.148 in) (0.158 in)
3.86 4.16 mm 4.9 mm
1st-2nd
(0.152 - 0.164 in) (0.193 in)
3.59 - 3.91 mm 4.1 mm
Rev.5th
(0.141 - 0.154 in) (0.161 in)
Clutch Hub and Insert Clearance

between the clutch hub and the insert.
226RS036

the 1st-2nd synchronizer assembly must be
replaced.
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance

Use a vernier caliper or thickness gauge to measure 226RS038
the clearance between the block ring and the insert. If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Standard Limit
1st-2nd 0.01 0.21 mm 0.3 mm
3rd-4th (0.004 - 0.0083 in) (0.012 in)
0.09 0.31 mm 0.4 mm
Rev-5th
(0.0035 - 0.0122 in) (0.016 in)
226RS037

the block ring and the insert must be replaced.
Mainshaft Run-out Gear Inside Diameter

Install the mainshaft to V-blocks. Standard Limit
Use a dial indicator to measure the mainshaft 1st 45.000 - 45.013 mm 45.100 mm
central portion run-out. 3rd (1.771 - 1.772 in) (1.776 in)
52.000 - 52.013 mm 52.100 mm
2nd
(2.047 - 2.048 in) (2.051 in)
48.000 - 48.013 mm 48.100 mm
Rev.
(1.889 - 1.890 in) (1.894 in)
32.000 - 32.013 mm 32.100 mm
5th
(1.259 - 1.260 in) (1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
Use a micrometer to measure the idler gear shaft
diameter.
Use an inside dial indicator to measure the idler
gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the

specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)
Gear Inside Diameter

Use an inside dial indicator to measure the gear
inside diameter.
226RS041
Calculate the idler gear and idler gear shaft

clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)
226RS040

the gear must be replace.
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.
226RS043
Reassembly
226RS042 1. Install center roller bearing (29) to counter gear
Move the clutch hub as far as possible to both the shaft (30).
right and the left. Apply engine oil to the bearing inner and outer
Note the dial indicator reading. circumferences.
If the measured value exceeds the specified limit, Install the roller bearing in the proper direction.
the clutch hub must be replaced. NOTE: Check that outer race moves only in the
Clutch Hub Spline Play direction of arrow.
Standard Limit
1st-2nd 0 - 0.1 mm 0.2 mm
3rd-4th (0 - 0.004 in) (0.008 in)
0 - 0.2 mm 0.3 mm
Rev. 5th
(0 - 0.008 in) (0.012 in)
Ball Bearing Play

Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the

following steps.
Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
Use bearing installer 5-8840-2194-0 to install the 5. Assemble 2nd inside ring (23), 2nd outside ring (22),
ring. and 2nd block ring (21) on 2nd gear (24).
Apply engine oil to the synchronizer ring friction
surfaces.
RTW47BSH000501
Legend
(1) Ring 226RS047
(2) Outer Race and Roller Assembly Legend

(3) Inner Race (1) Block Ring
(2) Outside Ring
3. Install bearing snap ring (27) to counter gear shaft
(30). (3) Inside Ring
4. Apply engine oil to the needle bearing (25) and the (4) 2nd Gear
2nd gear (24) thrust surfaces. (5) Needle Bearing
Install the needle bearing (25) and the 2nd gear (24) 6. Assemble 1st-2nd synchronizer assembly (20) by
to the mainshaft (26). performing the following steps:
The 2nd gear (24) dog teeth must be facing the 1. Check that the inserts (3) fit snugly into the
transmission rear side. clutch hub (5) insert grooves.
the inserts as shown in the illustration.
slide smoothly.
226RS046
266RS049 226RS050
7. Install the synchronizer assembly (20) to the There are three snap ring sizes available.
mainshaft (26). The snap rings are color coded to indicate their
The clutch hub face with the heavy boss must be thickness as shown in the figure.
facing the 2nd gear side.
226RS021
226RS048
Clutch Hub and Snap Ring Clearance
8. Install clutch hub snap ring(19) by performing the Standard: 0 - 0.1 mm (0 - 0.004 in)
following steps:
Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring. 1.80 mm (0.071 in) White
1.90 mm (0.075 in) Blue

ring (19) to the mainshaft (26).
mainshaft snap ring groove.
10. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st

outside ring (16), 1st inside ring (15), and 1st gear
(14).
Apply engine oil to the needle bearing, 1st gear 226RS054
thrust surfaces and synchronizer ring friction 11. Apply engine oil to the mainshaft ball bearing (12)
surfaces. and the mainshaft (26).
The 1st gear dog teeth must be facing the Install the ball bearing (12) and needle bearing collar
transmission front side. (11) to the mainshaft (26).
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
226RS055
(4) Outside Ring
(5) Block Ring
12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
226RS049
15. Select and install mainshaft snap ring(6) in the

following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.
226RS056
13. Install 3rd block ring (8).

14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 3rd gear side.
226RS058

The snap rings are color coded to indicate their
thickness as shown in the figure.
226RW221
16. Install top block ring (5).

Apply grease to the needle bearing (4) inner and
outer circumferences and install needle bearing (4)
in the top gear shaft (2).
17. Use a bench press to install the top gear shaft ball
bearing (3) to the top gear shaft (2).
226RS021

Standard: 0 - 0.1 mm (0 - 0.004 in)
1.80 mm (0.071 in) White
226RS059
The snap ring groove of the ball bearing (3) must be
1.90 mm (0.075 in) Blue facing the transmission front side.
Use a pair of snap ring pliers to install the snap 18. Use a pair of snap ring pliers to install the top gear
ring to the mainshaft. shaft snap ring (1) to the top gear shaft (2).
Main Data and Specifications

General Specifications
MUA 5G MUA 5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"
Torque Specifications
RTW47BLF001201
About arrow mark, refer to Transmission (MUA) Installation in this section.

Torque Specifications (Cont'd)
RTW47BLF000901
RTW47BLF000601
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Checkpoint Trouble Cause Countermeasure
NG Insufficient or improper gear Replenish or replace the gear

Gear oil
oil oil
OK
Flywheel pilot bearing NG Worn flywheel pilot bearing Replace the flywheel pilot
OK
Bearings (Mainshaft,
countershaft, and transfer NG
Worn or broken bearing(s) Replace the bearing(s)
shaft)
OK
Gears (Mainshaft,
NG Worn or scuffed gear tooth
countershaft, reverse idler Replace the gear(s)
contact surfaces
gear and transfer gears)
OK
Mainshaft splines NG Replace the main shaft and

Synchronizer clutch hub Worn splines
the synchronizer clutch hub
splines
OK
NG
Transmission Transmission misalignment Realign the transmission
2) NOISY OPERATION
NG Insufficient or improper engine Replenish or replace the gear

Gear oil (Metallic rattling)
oil oil
OK
Bearings (Hissing, thumping NG Worn or broken bearing(s) Replace the bearing(s)

or bumping)
OK
Gears (Growling, humming, or NG Worn, chipped, or cracked

Replace the gear(s)
grinding) gear(s)
OK
Free running gears seizing on

Gears (Squealing at high NG
the thrust face or the inner Replace the gear(s)
speeds)
face
OK
NG Lack of backlash between

Gears (Gear whining) Replace the gear(s)
meshing gears
2. HARD SHIFTING
NG Insufficient or improper gear Replenish or replace the

Gear oil
oil engine oil
OK
Clutch pedal free play NG Improper clutch pedal free Readjust the clutch pedal free
play play
OK
NG Hard operating change lever Repair or regrease the change

Change lever operation
caused insufficient grease lever assembly
OK
NG Worn change lever sliding Repair or replace the

Change lever play
portions applicable parts and regrease
OK
NG
Shift block sleeve movement Sleeve movement failure Repair or replace the sleeve
OK
Shift rod and quadrant box NG Worn shift rod and/or sliding Replace the shidt rod and/or
sliding faces, and other parts faces the quadrant box
Continued on the next page

Continued from the previous
OK
Shift arm and synchronizer NG Worn shift arm and/or

Replace the worn parts
sleeve synchronizer sleeve groove
OK
Mainshaft and countershaft NG Worn thrust washer, collar,

thrust play and/or gear thrust faces
OK
NG
Synchronizer assembly Worn synchronizer parts Replace the worn parts
3. WALKING OR JUMPING OUT OF GEAR
Insufficient stroke caused by

NG
Change lever play sliding position wear and Replace the worn parts
excessive play
OK
Detent ball NG Worn detent ball Replace the detent ball
OK
NG Repair or replace the detent

Detent spring Detent spring weak or broken
spring
OK
Shift rod and quadrant box NG Worn shift rod and/or sliding Replace the shift rod and/or
sliding faces faces the quadrant box
OK

OK


Continued from the previous page
OK
countershaft, and individual NG Worn or broken bearings(s) Replace the bearing(s)
gears)
OK
Mainshaft splines
Synchronizer clutch hub NG Replace the main shaft and
Worn splines
splines the synchronizer clutch hub
OK
NG
Synchronizer assembly Weak or broken spring Replace the spring
4. OIL LEAKAGE
NG Drain the oil to the correct

Oil level Oil level too high
level
OK
Gear oil NG Improper gear oil Replace the gear oil
OK
NG Tighten the plug(s) and

Drain plug and/or filler plug Loose plug(s)
replenish the oil
OK
NG Defective or improperly
Gaskets Replace the gasket(s)
installed gasket(s)
OK
NG Air breather not installed Install the air breather

Air breather
Air breather clogged Replace the air breather
OK
NG
Front cover oil seal Worn or scratched oil seal Replace the oil seal
OK
NG
Rear cover oil seal Worn or scratched oil seal Replace the oil seal
2)
Special Tools (4
TOOL NO. TOOL NO.

ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
5-8840-2159-0
5-8840-2155-0
Bearing remover Mainshaft end bearing
installer
5-8840-0015-0
5-8840-2027-0
Bearing
Puller
remover/installer
5-8840-2797-0
5-8840-2160-0
Rear case oil seal
Holding fixture
installer
5-8840-0026-0
5-8840-0003-0
Front cover oil seal
Holding fixture base
installer
5-8840-2156-0 9-8522-1165-0
Wrench Mainshaft collar remover
5-8840-0047-0
5-8840-0007-0
Tork bit wrench
Driver handle
(T45)
Service Precaution CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use
ONLY the exact part number for that application.
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
ISUZU will call out those fasteners that require a
RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out
COMPONENT AND WIRING LOCATION VIEW IN the fasteners that require thread lockers or thread
ORDER TO DETERMINE WHETHER YOU ARE sealant. UNLESS OTHERWISE SPECIFIED, do not
PERFORMING SERVICE ON OR NEAR THE SRS use supplemental coatings (Paints, greases, or
COMPONENTS OR THE SRS WIRING. WHEN YOU other corrosion inhibitors) on threaded fasteners or
ARE PERFORMING SERVICE ON OR NEAR THE fastener joint interfaces. Generally, such coatings
SRS COMPONENTS OR THE SRS WIRING, REFER adversely affect the fastener torque and the joint
TO THE SRS SERVICE INFORMATION. FAILURE TO clamping force, and may damage the fastener.
When you install fasteners, use the correct
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
tightening sequence and specifications. Following
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR these instructions can help you avoid damage to
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. parts and systems.
General Description
4)
MUA Transmission (4
A07R300003
The MUA is a constant mesh transmission, Principle parts of the transmission are the integral clutch
synchronized in all speeds. The transmission is housing, the intermediate plate, the rear case, and the
designed for a great reduction of the shift effort and the gears.
quietest possible operation. The transmission control box is built into the
transmission.
4)
Transmission (4
Disassembled View
RTW47BLF001001
Legend
(1) Gear Control Lever Knob (10) Transmission-Transfer Fixing Bolt
(2) Rear Floor Console (bucket) (11) Transfer Assembly
(3) Front Floor Console (12) Fuel Pipe Bracket
(4) Grommet Assembly (13) Slave Cylinder
(5) Gear Control Lever (14) Rear Mount Nut
(6) Rear Propeller Shaft (15) Transmission Crossmember
(7) Front Propeller Shaft (16) Starter (Diesel engine only)
(8) Exhaust Pipe Nut (Diesel engine) (17) Transmission Retaining Nut and Bolt
(9) Exhaust Pipe Assembly (6VE1) (18) Transmission Assembly
Removal 5. Remove grommet assembly (4).

1. Disconnect battery ground cable.
2. Remove gear control lever knob (1).
3. Remove rear floor console (2). (Bucket seat)
4. Remove front floor console (3).
745R300006
Legend RTW47BMH000101
(1) Knob
(2) Rear Floor Console
(3) Front Floor Console
6. Remove gear control lever (5). 11. Remove the exhaust pipe (9). (6VE1 only)
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.
9. Remove front propeller shaft (7).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
RTW37ASH000101

transfer.
Actuator connector
Car Speed Sensor
401RS023
10. Loosen the front exhaust pipe fixing nuts (8) at the
engine side but not remove them. (Diesel engine
only)
810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Back up Switch Connector
(3) Speed Sensor Connector
150R300004
(4) Actuator Connector
(5) 2W - 4W Switch Connector
(6) Neutral Switch Connector: Transfer
13. Remove transmission-transfer fixing bolts (10), and 16. Remove slave cylinder (13) and put aside it.
remove the transfer assembly (11) from the
transmission.
transmission.
Neutral switch; Transmission
Back up Switch
2W-4W Switch
Neutral Switch; Transfer
15. Remove the fuel pipe brackets (12) with pipes from
the transmission (18).
Diesel engine
220LV019
17. Support transmission with a transmission jack.
220R300012
Legend
(1) Bolt
(2) Nut
6VE1, C24NE
220RS0001
18. Remove engine rear mount nuts (14) from

transmission crossmember (15).
Scan-2
19. Remove engine rear mount bolts fixing 22. Remove starter (16). (Diesel engine only)
transmission.
060L100070
220R300009
20. Remove the middle part of transmission 23. Use the clutch release bearing remover 5-8840-
crossmember (15) by removing four fixing bolts and 2291-0 (J-39207) to disconnect the clutch release
nuts. bearing from the clutch pressure plate. (6VE1 only)
220RW109
501R30007
21. Take out the rear support rubber. Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.
NOTE: Be sure not to insert the remover between the

wedge collar and the clutch.
220RW019
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
24. Remove transmission retaining nuts and bolts(17).

Remove transmission assembly (18) from the
vehicle.
Installation
220RW063 1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft with the clutch driven plate
spline.
220RW064
4. Install the transmission assembly (18) to the engine.

Tighten the transmission nuts and bolts as shown in
the figure.
Diesel engine
RTW37BLF000901
6VE1
RTW37BLF0001
RTW37BLF000201
5. Apply a force of about 113N (26 Ib) to the tip of the

shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.
220RS006
6. Install starter(16).(Diesel engine)

6VE1, C24NE
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N m (7.7 kg m/56 lbft)
7. Install the rear support rubber on the transmission
and tighten the bolts to the specified torque.
ft)
8. Install the middle part of transmission crossmember
(15) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N m (6.8 kg
m/49 lbft)
9. Install engine rear mount nuts (14).
m/38 lbft)
Remove the transmission jack from transmission
side. Scan-2
10. Apply grease to top hole portion of the shift fork. 12. Connect transmission harness connectors and clips.
Install slave cylinder (13) and tighten the bolts to the Connector: transfer neutral switch, 2W - 4W switch,
specified torque. backup switch, transmission neutral switch.
Torque: 76 N m (7.7 kgm/56 lbft)

11. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe
brackets
Torque: Bolt & Nut m (7.7 kg
76 N m/56 lb
ft)
Nut m (3.8 kg
37 N m/28 lb
ft)
Diesel engine
810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Backup Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W - 4W Switch connector
220R300012 (6) Neutral Switch Connector: Transfer
Legend
(1) Bolt 13. Apply grease (BESCO L2 or equivalent) on the
splined portion of the output shaft.
(2) Nut
14. Connect the transfer to the transmission.
15. Install the transmission-transfer bolts and nut and 18. Install the exhaust pipe (9). (6VE1)
tighten them to the specified torque. m (6.8 kg
ft)
m (4.2 kg
ft)
RTW37ASH000101
261R300005 19. Install front propeller shaft (7).

Refer to the section Front Propeller Shaft.
20. Install rear propeller shaft (6).
Torque: 63 N m (6.4 kgm/46 lbft)
21. Install the center bearing on crossmember.
ft)
22. Install gear control lever (5).
m (1.9 kg
ft)
21. Install grommet assembly (4).

Torque: Screw m (0.14 kg
1.4 N m/12 lb
in)
Nut m (0.7 kg
7 N m/61 lb
in)
RTW47BMH000101
Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front
24. Install front floor console (3) and rear floor console
(2).
25. Install gear control lever knob (1).
To the female thread portion, adhesive (TB1344 or
LOCTITE 222 or equiv.) of 3 - 4 drops to be applied
and transmission knob tightened.
Torque: 9 N m (0.9 kgm/78 lb in)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
26. Connect battery ground cable.
Transmission Case
Major Component
RTW47BLF000101
Legend
(1) Gear Control Box Assembly and Gasket (8) Front Cover (with Oil Seal)
(2) Rear Case Assembly (9) Top Gear Bearing Snap Ring
(3) Intermediate Plate with Gear Assembly (10) Release Bearing : C24NE
(4) Transmission Case (11) Shift Fork : C24NE
(5) Release Bearing (with Spring): 4JH1-TC (12) Fulcrum Bridge : 6VE1
(6) Shift Fork: 4JH1-TC (13) Release Bearing : 6VE1
(7) Counter Front Bearing Snap Ring (14) Shift Fork : 6VE1
Disassembly 7. Remove the fulcrum bridge from the transmission

1. Clean the exterior of the unit with solvent. case. (6VE1)
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring (5)
from the transmission case.
4. Remove the shift fork, and boot. (Diesel engine,
C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)
RTW37ASH0002
Legend
(1) Fulcrum bridge
8. Remove the front cover (8) and gasket from the
transmission case.
9. Remove snap ring (7) fixing counter front bearing.
ring (9) fixing top gear bearing.
RTW47BSH000601
Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
226RS001
11. Remove gear control box assembly (1).

12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).
Rear Oil Seal Replacement
220R300026
220R300025
Legend Notes When Tightening the Bolt:

(1) Installer 5-8840-2797-0 After cleaning the bolt hole, dry it thoroughly with air.
(2) Grip 5-8840-0007-0 After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
1. Remove the oil seal from the rear case and discard liquid gasket (LOCTITE 242) or its equivalent on
the used oil seal. them before tightening it.
2. Apply engine oil to new oil seal outer surfaces. 4. Install a new gasket and gear control box assembly
(1).
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip. Install the harness clips and brackets and then
tighten four new gear control box bolts to the
4. Use the oil seal installer 5-8840-2797-0 and grip 5-
specified torque.
8840-0007-0 to install the oil seal to the rear case.
Reassembly m (2.0 kg
ft)
1. Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transmission case (4),
intermediate plate (3) and rear case (2) fitting
surfaces.
2. Install the intermediate plate with gear assembly (3)
to the transmission case (4).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal (2) on the
intermediate plate with gear (3) by performing the
following steps.
Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
Tighten the transmission rear case bolts and 261R300004
nuts to the specified torque.

m (3.8 kg
ft)
5. Install top gear bearing snap ring (9) and counter 8. Apply molybdenum disulfide type grease to the
front bearing snap ring (7). areas as shown in the figure and install shift fork (6).
Use a pair of snap ring pliers to install the snap (Diesel engine, C24NE)
rings to the mainshaft and countershaft.
The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal (8).
Front Cover Oil Seal Replacement
Remove the oil seal from the front cover.
Apply engine oil to a new oil seal outer
circumference.
Apply recommended grease to the oil seal lip.
Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
F07L100026
9. Install the fulcrum bridge to the transmission case.

(6VE1)
m (3.9 kg
ft)
220R3000020
RTW37ASH0002
Legend
(1) Fulcrum bridge
10. Apply molybdenum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.
(6VE1)
11. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)
12. Install the washer and snap pin. (6VE1)
RTW47BMH000201
13. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover,

joining it to the shift fork.
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View
RTW47BLF000501
Legend
(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly
Disassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent balls
from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when

pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.
220RS011
2. Remove spring (4).

3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).
Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift

rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.

Make the necessary adjustments, and part
Shift Arm Thickness
Use a micrometer to measure the shift arm
thickness.
the shift arm must be replaced.
Shift Arm Thickness
Standard Limit
9.60 - 9.85 mm
1st-2nd
(0.378 - 0.388 in) 9.0 mm
3rd-4th 9.60 - 9.80 mm (0.354 in)
Rev.5th (0.378 - 0.386 in)
220RS012

Use a spring tester to measure the detent spring
tension.
Compressed height Standard
87.2 - 97.1 N
20 mm (0.787 in)
(19.6 - 21.8 lb)
230RS006

Use a vernier caliper to measure the detent spring
free length.
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)
SOUTH AFRICA 5th-Rev Only 220RS013

SOUTH AFRICA 5th-RV Only
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Compressed Standard
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in)
93.5 103.3 N
Outer 20 mm (0.787 in)
(21.0 23.3 lb)
26.4 36.3 N
Inner 20 mm (0.787 in)
(5.9 8.2 lb)
Reassembly 4. Install spring (4).

1. Install rev-5th shift arm and reverse inhibitor (6) and 5. Put detent balls (3) in the intermediate plate holes.
rev-5th shift rod (5). Apply oil to the detent balls.
Apply oil to the reverse inhibitor inner surface. 6. Install detent springs (2) and detent spring plate and
Install the shift rod in the intermediate plate (12). gasket (1).
Hold a round bar against the shift rod end lower Install a new gasket and the detent spring plate.
face to protect it against damage. Tighten the detent spring plate bolts to the
Install a new spring pin. specified torque.
Never reinstall the used spring pin. m (2.5 kg
ft)
plate (12).
intermediate plate (12).
2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9)
to intermediate plate and gear assembly (12).
3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).
plate and gear assembly (12).
Install the 3rd-4th shift rod (8) in the intermediate
plate (12).
intermediate plate.
Install the interlock pin (11) and then 1st-2nd
shift rod (7) in the intermediate plate (12).
intermediate plate.
Hold a round bar against the shift rod end lower 220RS030
face to protect it against damage. Legend

Install a new spring pin. (1) Warped
Never reinstall the used spring pin.
230RS007
Reverse Gear and 5th Gear

Disassembled View
226R300024
Legend
(1) Collar Snap Ring (15) Counter 5th Gear
(2) Oil Seal Collar (16) Counter Reverse Gear
(3) Ball Bearing (17) 5th Gear
(4) Retainer (18) 5th Block Ring
(5) Thrust Plate (19) Needle Bearing
(6) Thrust Washer and Lock Ball (20) Mainshaft Nut
(7) Reverse Idler Gear Snap Ring (21) Rev-5th Synchronizer Assembly
(8) Reverse Idler Gear Assembly (22) Reverse Block Ring
(9) Idle Shaft Pin (23) Reverse Gear
(10) Thrust Washer (24) Needle Baring
(11) Reverse Idler Gear (25) Bearing Plate and Screw
(12) Reverse Idler Shaft (26) Bearing Snap Ring
(13) Bearing Snap Ring (27) Intermediate Plate
(14) Ball Bearing
Disassembly 6. Remove the reverse idler gear assembly (8) from

1. Use a pair of snap ring pliers to remove the collar the intermediate plate (27).
snap ring (1).
2. Set the retaining ring remover 5-8840-2158-0 and
puller 5-8840-2027-0 to the retainer (4) and the
mainshaft end.
226RS005
7. Remove idle shaft pin (9), thrust washer (10),

reverse idler gear (11), and reverse idler shaft (12).
ring (13).
262RW079
3. Remove the retainer (4) together with the bearing 9. Attach a universal puller to the counter gear shaft.
(3) and the oil seal collar (2). Use a universal puller to remove the ball bearing
The universal puller may be used in place of the (14) and the counter 5th gear (15).
retaining ring remover.
4. Remove thrust plate (5) and thrust washer and lock
ball (6).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (7).
226RS006
10. Remove counter reverse gear (16).
226RS004
11. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).
226RW210
Use the mainshaft nut wrench 5-8840-2156-0 to

226RS007 remove the mainshaft nut (20).
12. Remove the mainshaft nut (20) according to
following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd

gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
13. Use screw drivers between the reverse gear (23)

and bearing plate (25) to remove the Rev-5th
synchronizer assembly (21) together with reverse
block ring (22) and reverse gear (23).
226RS011
17. Hold the snap ring open with the pliers.

Push the intermediate plate (27) toward the rear of
the transmission to remove it.
226RS010
The bearing snap ring will come free.
14. Remove needle bearing (24).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(25) from the Inspection and Repair
intermediate plate. Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (27) on the gear
assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).
226RW212
2. Install bearing snap ring (26). 5. Assemble rev-5th synchronizer assembly (21) by
3. Apply recommended thread locking agents performing the following steps.
(LOCTITE 242) or its equivalent to each of the 1. Turn the clutch hub face (1) toward the sleeve
bearing plate screw threads. groove (2) (rear side) on the outer
Install bearing plate and screw (25). circumference.
Tighten the screws to the specified torque by using 2. Check that the inserts (3) fit snugly into the
torx bit wrench 5-8840-0047-0. clutch hub (5) ring insert grooves.
m (1.5 kg
ft) the inserts as shown in the illustration.
slide smoothly.
5. Install the synchronizer assembly (21) to the
mainshaft.
facing the reverse gear side.
220RW137
4. Install needle bearing (24), reverse gear (23), and

reverse block ring (22).
226RS013
226RS049
6. Mesh the 1st-2nd and 3rd-4th synchronizers with 8. Use a punch to stake the mainshaft nut (20).
both the 1st and 3rd gears (double engagement).
226RW153
226RS015 9. Install needle bearing (19), 5th block ring (18), and
This will prevent the mainshaft from turning. 5th gear (17).
7. Install the new mainshaft hub nut. 10. Apply engine oil to the counter reverse gear (16) and
Use the mainshaft nut wrench 5-8840-2156-0 to the reverse gear (23).
tighten the mainshaft nut (20) to the specified Install the counter reverse gear (16) to the counter
torque. shaft.
m (14 kg
ft) The reverse gear projection must be facing the
intermediate plate.
226RW214
226RW151
11. Install the counter 5th gear (15) to the counter shaft. There are six snap ring sizes available.
The snap rings are color&dash;coded to indicate
their thickness.
226RS019
12. Install ball bearing (14) and bearing snap ring (13)
by performing the following steps: 226RS021
Select the snap ring which will provide the Ball Bearing and Snap Ring Clearance
minimum clearance between the ball bearing Standard: 0 - 0.15 mm (0 - 0.0059 in)
and the snap ring.
1.1 mm (0.043 in) White
1.3 mm (0.051 in) Blue
1.4 mm (0.055 in) Pink
1.5 mm (0.059 in) Green
1.6 mm (0.063 in) Brown

ring(13) to the counter gear shaft.
counter gear shaft snap ring groove.
13. Assemble reverse idler shaft (12), reverse idler gear
(11), thrust washer (10), and idle shaft pin (9) into
reverse idler gear assembly (8).
The trust washer should be assembled as oil groove
226RS020
faces to gear side.
14. Select reverse idler gear snap ring (7) which will Use a pair of snap ring pliers to install the snap
provide the minimum clearance between the ring to the reverse idler shaft.
intermediate plate (27) and the snap ring (7). The snap ring must be fully inserted into the
reverse idler shaft snap ring groove.
15. Install thrust washer and lock ball (6) by performing
the following steps:
Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in))
Measure clearance "A" as shown in the figure.
226RS022

The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
1.2 mm (0.047 in) White
1.3 mm (0.051 in) Yellow 226RS023
Select appropriate thrust washer from chart.

1.4 mm (0.055 in) Blue
There are four thrust washer sizes available.
Thrust Washer Availability
Thickness Color Clearance
A mm (in)
mm (in) Coding mm (in)
8.05 - 8.1 0.15 - 0.25
7.9 (0.311) White
(0.317-0.319) (0.006-0.010)
8.1 - 8.2 0.1 - 0.25
8.0 (0.315) Yellow
(0.319-0.323) (0.004-0.010)
8.2 - 8.3 0.1 - 0.25
8.1 (0.319) Green
(0.323-0.327) (0.004-0.010)
8.3 - 8.36 0.1 - 0.21
8.2 (0.323) Blue
(0.327-0.329) (0.004-0.008)
The thrust washers are color coded to indicate

their thickness as shown in the figure.
226RS021
18. Apply engine oil to the oil seal collar inner

circumference.
Install the oil seal collar (2) to the mainshaft by using
the installer 5-8840-2159-0.
19. Install the oil seal collar snap ring (1).
226RS024
Apply grease to the thrust washer and the lock

ball.
Install the thrust washer and the lock ball.
16. Install thrust plate (5) and retainer (4).
17. Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing (3) to the mainshaft.
226L100002
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
Legend
(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring
(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft
Disassembly 6. Use a bench press and the bearing remover 5-8840-

1. Use a pair of snap ring pliers to remove the top gear 0015-0 to remove the 3rd-4th synchronizer
shaft snap ring(1). assembly (7) as a set.
2. Remove top gear shaft(2) with ball bearing(3). Disassemble the synchronizer assembly.
0015-0 to remove the ball bearing(3).
226RW217
Legend
226RW216
(1) Springs
4. Remove needle bearing (4) and top block ring (5), (2) Sleeve
mainshaft snap ring. (3) Clutch Hub
5. Use a pair of snap ring pliers to remove the (4) Inserts
mainshaft snap ring (6).
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RS008
226RW218
9.Disassemble 1st inside ring (15), 1st outside ring (16), 13. Remove needle bearing (25) from mainshaft (26).
and 1st block ring (17). 14. Remove bearing snap ring (27).
10.Remove needle bearing (18). 15. Remove the front roller bearing (28) by performing
11.Use a pair of snap ring pliers to remove the clutch the following steps.
hub snap ring (19).
Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.
Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RS031
12.Use bench press and the bearing remover 5-8840-

0015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
Disassemble the synchronizer assembly. 226RW219
16. Remove center roller bearing (29) from counter gear

shaft (30).
226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

Make the necessary adjustments, repairs, and part
between the block ring and the dog teeth.
226RS035

the block ring must be replaced.
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
1st-2nd Synchronizer (3-CONE) Block and Insert Clearance

Use a thickness gauge to measure the clearance Standard Limit
between the block ring and the dog teeth. 3.46 - 3.76 mm 4.0 mm
3rd-4th
(0.136 - 0.148 in) (0.158 in)
3.86 4.16 mm 4.9 mm
1st-2nd
(0.152 - 0.164 in) (0.193 in)
3.59 - 3.91 mm 4.1 mm
Rev.5th
(0.141 - 0.154 in) (0.161 in)

between the clutch hub and the insert.
226RS036

the 1st-2nd synchronizer assembly must be
replaced.
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance

Use a vernier caliper or thickness gauge to measure
226RS038
the clearance between the block ring and the insert.
the clutch hub and the insert must be replaced.
Standard Limit
1st-2nd 0.01 0.21 mm 0.3 mm
3rd-4th (0.004 - 0.0083 in) (0.012 in)
0.09 0.31 mm 0.4 mm
Rev-5th
(0.0035 - 0.0122 in) (0.016 in)
226RS037

the block ring and the insert must be replaced.
Mainshaft Run-out Gear Inside Diameter

Install the mainshaft to V-blocks. Standard Limit
Use a dial indicator to measure the mainshaft 1st 45.000 - 45.013 mm 45.100 mm
central portion run-out. 3rd (1.771 - 1.772 in) (1.776 in)
52.000 - 52.013 mm 52.100 mm
2nd
(2.047 - 2.048 in) (2.051 in)
48.000 - 48.013 mm 48.100 mm
Rev.
(1.889 - 1.890 in) (1.894 in)
32.000 - 32.013 mm 32.100 mm
5th
(1.259 - 1.260 in) (1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
Use a micrometer to measure the idler gear shaft
diameter.
Use an inside dial indicator to measure the idler
gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the

specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)
Gear Inside Diameter

Use an inside dial indicator to measure the gear
inside diameter.
226RS041
Calculate the idler gear and idler gear shaft

clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)
226RS040

the gear must be replace.
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.
226RS043
Reassembly
226RS042 1. Install center roller bearing (29) to counter gear
Move the clutch hub as far as possible to both the shaft (30).
right and the left. Apply engine oil to the bearing inner and outer
Note the dial indicator reading. circumferences.
If the measured value exceeds the specified limit, Install the roller bearing in the proper direction.
the clutch hub must be replaced. NOTE: Check that outer race moves only in the
Clutch Hub Spline Play direction of arrow.
Standard Limit
1st-2nd 0 - 0.1 mm 0.2 mm
3rd-4th (0 - 0.004 in) (0.008 in)
0 - 0.2 mm 0.3 mm
Rev. 5th
(0 - 0.008 in) (0.012 in)
Ball Bearing Play

Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the

following steps.
Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
Use bearing installer 5-8840-2194-0 to install the 5. Assemble 2nd inside ring (23), 2nd outside ring (22),
ring. and 2nd block ring (21).
Apply engine oil to the synchronizer ring friction
surfaces.
226RS045
Legend
(1) Ring 226RS047
(2) Outer Race and Roller Assembly Legend

(1) Block Ring
(3) Inner Race
(2) Outside Ring
3. Install bearing snap ring (27) to counter gear shaft (3) Inside Ring
(30). (4) 2nd Gear
4. Apply engine oil to the needle bearing (25) and the (5) Needle Bearing
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24) 6. Assemble 1st-2nd synchronizer assembly (20) by
to the mainshaft (26). performing the following steps:
The 2nd gear (24) dog teeth must be facing the 1. Check that the inserts (3) fit snugly into the
transmission rear side. clutch hub (5) insert grooves.
the inserts as shown in the illustration.
slide smoothly.
226RS046
266RS049 226RS050
7. Install the synchronizer assembly (20) to the There are three snap ring sizes available.
mainshaft (26). The snap rings are color coded to indicate their
The clutch hub face (with the heavy boss) must be thickness as shown in the figure.
facing the 2nd gear side.
226RS021
226RS048 Clutch Hub and Snap Ring Clearance

8. Install clutch hub snap ring(19) by performing the Standard: 0 - 0.1 mm (0 - 0.004 in)
following steps:
Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring. 1.80 mm (0.071 in) White
1.90 mm (0.075 in) Blue

ring (19) to the mainshaft (26).
10. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st

outside ring (16), 1st inside ring (15), and 1st gear
(14).
Apply engine oil to the needle bearing, 1st gear 226RS054
thrust surfaces and synchronizer ring friction 11. Apply engine oil to the mainshaft ball bearing (12)
surfaces. and the mainshaft (26).
The 1st gear dog teeth must be facing the Install the ball bearing (12) and needle bearing collar
transmission front side. (11) to the mainshaft (26).
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
226RS055
(4) Outside Ring
(5) Block Ring
12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
226RS049
15. Select and install mainshaft snap ring(6) in the

following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.
226RS056
13. Install 3rd block ring (8).

14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 3rd gear side.
226RS058

The snap rings are color coded to indicate their
thickness as shown in the figure.
226RW221
16. Install top block ring (5).

Apply grease to the needle bearing (4) inner and
outer circumferences and install needle bearing (4)
in the top gear shaft (2).
17. Use a bench press to install the top gear shaft ball
bearing (3) to the top gear shaft (2).
226RS021

Standard: 0 - 0.1 mm (0 - 0.004 in)
1.80 mm (0.071 in) White
226RS059
The snap ring groove of the ball bearing (3) must be
1.90 mm (0.075 in) Blue facing the transmission front side.
Use a pair of snap ring pliers to install the snap 18. Use a pair of snap ring pliers to install the top gear
ring to the mainshaft. shaft snap ring (1) to the top gear shaft (2).
Main Data and Specifications

General Specifications
MUA5G MUA5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"
Torque Specifications
RTW47BLF001101
About arrow mark, refer to Transmission (MUA) Installation in this section.

RTW47BLF000801
RTW47BLF000601
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
NG Insufficient or improper gear Replenish or replace the gear

Gear oil
oil oil
OK
Flywheel pilot bearing NG Worn flywheel pilot bearing Replace the flywheel pilot
OK
countershaft, and transfer NG
Worn or broken bearing(s) Replace the bearing(s)
shaft)
OK
Gears (Mainshaft,
NG Worn or scuffed gear tooth
countershaft, reverse idler Replace the gear(s)
contact surfaces
gear and transfer gears)
OK
Mainshaft splines NG Replace the main shaft and

Synchronizer clutch hub Worn splines
the synchronizer clutch hub
splines
OK
NG
Transmission Transmission misalignment Realign the transmission
2) NOISY OPERATION
NG Insufficient or improper engine Replenish or replace the gear

Gear oil (Metallic rattling)
oil oil
OK
Bearings (Hissing, thumping NG Worn or broken bearing(s) Replace the bearing(s)

or bumping)
OK
Gears (Growling, humming, or NG Worn, chipped, or cracked

Replace the gear(s)
grinding) gear(s)
OK
Free running gears seizing on

Gears (Squealing at high NG
the thrust face or the inner Replace the gear(s)
speeds)
face
OK
NG Lack of backlash between

Gears (Gear whining) Replace the gear(s)
meshing gears
2. HARD SHIFTING
NG Insufficient or improper gear Replenish or replace the

Gear oil
oil engine oil
OK
Clutch pedal free play NG Improper clutch pedal free Readjust the clutch pedal free
play play
OK
NG Hard operating change lever Repair or regrease the change

Change lever operation
caused insufficient grease lever assembly
OK
NG Worn change lever sliding Repair or replace the

Change lever play
portions applicable parts and regrease
OK
NG
Shift block sleeve movement Sleeve movement failure Repair or replace the sleeve
OK
Shift rod and quadrant box NG Worn shift rod and/or sliding Replace the shidt rod and/or
sliding faces, and other parts faces the quadrant box

Continued from the previous
OK

OK

OK
NG
Synchronizer assembly Worn synchronizer parts Replace the worn parts
3. WALKING OR JUMPING OUT OF GEAR
Insufficient stroke caused by

NG
Change lever play sliding position wear and Replace the worn parts
excessive play
OK
Detent ball NG Worn detent ball Replace the detent ball
OK
NG Repair or replace the detent

Detent spring Detent spring weak or broken
spring
OK
Shift rod and quadrant box NG Worn shift rod and/or sliding Replace the shift rod and/or
sliding faces faces the quadrant box
OK

OK


Continued from the previous page
OK
countershaft, and individual NG Worn or broken bearings(s) Replace the bearing(s)
gears)
OK
Mainshaft splines
Synchronizer clutch hub NG Replace the main shaft and
Worn splines
splines the synchronizer clutch hub
OK
NG
Synchronizer assembly Weak or broken spring Replace the spring
4. OIL LEAKAGE
NG Drain the oil to the correct

Oil level Oil level too high
level
OK
Gear oil NG Improper gear oil Replace the gear oil
OK
NG Tighten the plug(s) and

Drain plug and/or filler plug Loose plug(s)
replenish the oil
OK
NG Defective or improperly
Gaskets Replace the gasket(s)
installed gasket(s)
OK
NG Air breather not installed Install the air breather

Air breather
Air breather clogged Replace the air breather
OK
NG
Front cover oil seal Worn or scratched oil seal Replace the oil seal
OK
NG
Rear cover oil seal Worn or scratched oil seal Replace the oil seal
4)
Special Tools (4
TOOL NO. TOOL NO.

ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
5-8840-2159-0
5-8840-2158-0
Mainshaft collar remover Mainshaft end bearing
installer
5-8840-0015-0
5-8840-2027-0
Bearing
Puller
remover/installer
5-8840-2797-0
5-8840-2160-0
Rear case oil seal
Holding fixture
installer
5-8840-0026-0
5-8840-0003-0
Front cover oil seal
Holding fixture base
installer
5-8840-2156-0 9-8522-1165-0
Wrench Mainshaft collar remover
5-8840-0047-0
5-8840-0007-0
Tork bit wrench
Driver handle
(T45)
No. TFMUA-WE-0431

Manual Transmission (MUA Models) PDF

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WORKSHOP MANUAL

Service Precaution CAUTION: Always use the correct fastener in the

2. Insert the splined yoke into the transimission

Torque : 63 Nm (6.4 kgm/46 lbft)

Removal 5. Remove grommet assembly (4).

11. Disconnect harness connectors and clips on the

14. Support transmission with a transmission jack.

15. Remove engine rear mount nuts (11) fixing on cross

NOTE: Be sure not to insert the remover between the

21. Remove transmission retaining nuts and bolts(16).

4. Install the transmission assembly (17) to the engine.

5. Apply a force of about 113N (26 Ib) to the tip of the

6. Install starter(15). (Diesel engine only)

14. Install the exhaust pipe (8). (6VE1)

15. Install rear propeller shaft (6).

Disassembly 7. Remove the fulcrum bridge from the transmission

11. Remove the speedometer sensor (2).

5. Install the O-ring (4) to the speedometer driven gear

10. Install a new gasket and front cover (9) to the

17. Install the release bearing (6) on the front cover,

Be careful not to lose the interlock pins, when

2. Remove spring (4).

Remove the rev-5th, 1st-2nd and 3rd-4th shift

Use a spring pin remover to remove the shift

Inspection and Repair

Detent Spring Tension

Detent Spring Free Length

SOUTH AFRICA 5th-Rev Only SOUTH AFRICA 5th-RV Only

Reassembly 4. Install spring (4).

face to protect it against damage. Legend

Reverse Gear and 5th Gear

(21) 5th Block Ring (26) Reverse Gear

Disassembly 6. Remove the reverse idler gear assembly (11) from

7. Remove idle shaft pin (12), thrust washer (13),

10. Remove counter reverse gear (19).

Use the mainshaft nut wrench 5-8840-2156-0 to

Engage the 3rd-4th synchronizer with the 3rd

13. Use screw drivers between the reverse gear (26)

17. Hold the snap ring open with the pliers.

4. Install needle bearing (27), reverse gear (26), and

Use a pair of snap ring pliers to install the snap

There are three snap ring sizes available.

Select appropriate thrust washer from chart.

The thrust washers are color coded to indicate

19. Install the bearing snap ring (1).

Apply grease to the thrust washer and the lock

Disassembly 6. Use a bench press and the bearing remover 5-8840-

12.Use bench press and the bearing remover 5-8840-

16. Remove center roller bearing (29) from counter gear

Inspection and Repair

If the measured value exceeds the specified limit,

1st-2nd Synchronizer (3-CONE) Block and Insert Clearance

Clutch Hub and Insert Clearance

If the measured value exceeds the specified limit,

Block Ring and Insert Clearance

If the measured value exceeds the specified limit,

Mainshaft Run-out Gear Inside Diameter

If the measured mainshaft run-out exceeds the

Gear Inside Diameter

Calculate the idler gear and idler gear shaft

If the measured value is less than the specified limit,

Clutch Hub Spline Play

Ball Bearing Play