SECTION 7B - MANUAL TRANSMISSION MUA 5C (4X4)
Service Precaution
General Description
Diagnosis (MUA)
Transmission (MUA)
Disassembled View
Removal
Installation
Transmission Case and Transfer Case
Major Component (MUA)
Disassembly
Reassembly
Intermediate Plate with Gear Assembly,
Detent, Shift Arm, and Interlock Pin (MUA)
Disassembled View
Disassembly
Inspection and Repair
Reassembly
Reverse Gear and 5th Gear (MUA)
Disassembled View
Disassembly
Inspection and Repair
Reassembly
Top Gear Shaft, Main Gear Shaft, and
Counter Gear Shaft (MUA)
Disassmebled View
Disassembly
Inspection and Repair
Reassembly
Main Data and Specifications
Special Tools (MUA)
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SER VICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener . When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
MUA5C Transmission
For 6VD1
A07RX005
For X22SE
A07RX008
The MUA5C is a constant mesh transmission,
synchronized in all speeds. The transmission is designed
for a great reduction of the shift effort and the quietest
possible operation.
Principle parts of the transmission are the integral clutch
housing, intermediate plate, the transfer case, the rear
cover, and the gears.
The transmission control box and transfer control box are
built into the transmission and transfer case.
Diagnosis (MUA)
Condition Possible cause Correction
Abnormal noise Flywheel pilot bearing worn Replace
Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft) Replace
Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Replace
Splines worn (Mainshaft,
synchronizer clutch hub) Replace
Gear or bearing thrust face seized Replace
Lack of backlash between meshing
gears Replace
Hard Shifting Improper clutch pedal free play Readjust
Change lever sliding portions worn Repair or replace Regrease
Shift block, shift rod and/or control
box sliding faces worn Replace
Shift arm and synchronizer sleeve
groove worn Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Synchronizer parts worn Replace
Walking or Jumping out of gear Detent ball worn Replace
Detent spring weakened or broken Replace
Shift rod and/or control box sliding
faces worn Replace
Shift arm and synchronizer sleeve
groove worn Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Bearings worn or broken Replace
Splines worn (Mainshaft,
synchronizer hub) Replace
Synchronizer spring weakened or
broken Replace
Oil leakage Loose drain plug(s) and/or filler
plug(s) Tighten Replenish oil
Defective or improperly installed
gasket(s) Replace
Oil seal worn or scratched Replace
Transmission (MUA)
Disassembled View
220RX006
Legend
(1) Gear Control Lever Knob
(2) Transfer Control Lever Knob
(3) Center Console
(4) Grommet Assembly
(5) Gear Control Lever and Transfer Control Lever
(6) Transfer Protector
(7) Rear Propeller Shaft
(8) Front Propeller Shaft
(9) Center Exhaust Pipe
(10) Harness Clamp
(11) Harness Heat Protector
(12) Slave Cylinder
(13) Dust Cover
(14) Rear Mount Nut
(15) Third Crossmember
(16) Starter
(17) Flywheel Undercover
(18) Transmission Retaining Nut and Bolt
(19) Transmission
Removal
NOTE: Befor removing transmission assembly from
vehicle, change the transfar mode to 2WD using the 4WD
push button on dash panel.
1.Disconnect battery ground cable.
2.Remove gear control lever knob(1).
3.Remove transfer control lever knob(2).
4.Remove lower cluster assembly.
740RW021
5.Remove rear console.
256RW045
6.Remove center console(3).
F07RW018
7.Remove grommet assembly(4).
F07RW016
8.Remove gear control lever(5) and transfer control
lever(5).
9.Raise and support vehicle with suitable stands.
Remove transfer protector(6).
150RX010
10.Remove rear propeller shaft(7).
NOTE: Apply alignment marks on the flange at both front
and rear sides.
401RW008
11.Remove front propeller shaft(8).
NOTE: Apply alignment marks on the flange at both front
and rear sides.
401RW007
12.Remove center exhaust pipe(9) (6VD1).
150RX009
13.Loosen the exhaust pipe nuts at the exhaust manifold
side (X22SE).
14.Disconnect transmission harness connectors and
clip.
Connector: Transfer switch, 2–4 actuator, speed
sensor, back up switch 1–2 indicator switch (6VD1)
and 3–4 indicator switch (6VD1).
15.Remove transmission harness clamps(10) from the
transmission case and bracket.
220RS028
16.Remove harness heat protector(11) (6VD1).
17. Remove slave cylinder(12) and flexible hose fixing
bracket (X22SE).
205RW001
18.Remove dust covers(13) (6VD1).
19.Support transmission with a transmission jack.
220RS001
20.Remove engine rear mount nuts(14) from third
crossmember.
F07RW008
21.Remove third crossmember(15) by removing six
fixing bolts.
22.Remove starter(16) (6VD1).
23.Remove flywheel under cover(17). 6VD1:3 pieces,
X22SE:1 piece.
24.Use clutch release bearing remover 5–8840–2291–0
to disconnect the clutch release bearing from the
clutch pressure plate (6VD1).
220RW109
25.Pull the shift fork toward the transmission to press the
clutch release bearing against the clutch pressure
plate (6VD1).
26.Insert the clutch release bearing remover
5–8840–2291–0 between the wedge collar and the
release bearing (6VD1).
NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RS003
27.Turn the remover to separate the release bearing
(6VD1).
220RX007
28. Remove the front skid plate and then remove one
right side bolt from the front (X22SE).
29.Remove transmission retaining nut and bolts(18).
Remove transmission(19) from the vehicle.
Installation
1.Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2.Drain coolant and disconnect the lower heater pipe
from the hose on the back of the engine at right side
(X22SE).
3.Turn the heater pipe assembly backward not to
interfere with the transmission (X22SE).
4.Disconnect fuel pipes from hoses at the front side of
the transmission (X22SE).
5.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.
6.Align the top gear shaft spline with the clutch driven
plate spline.
220RS007
7.Install the transmission to the engine.
8.Connect the heater pipe with the hose (X22SE).
9.Tighten the transmission nut and bolts as shown in
the figure.
225RX004
225RX005
10.Connect the fuel pipes with the hoses (X22SE).
11.Apply a force of 59 – 78 N (6.0 – 8.0 kg/
13.2 – 17.6 lb) to the tip of the shift fork in the
direction of the transmission to engage the clutch
pressure plate and release bearing (6VD1).
NOTE: A click 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 side while applying
a force of about 25 N (2.5 kg/5.5 lb). If the shift fork will
not move, then they are securely engaged (6VD1).
220RS006
12.Install flywheel under cover(17). 6VD1: 3 pieces,
X22SE: 1 piece.
Torque: 8 N·m (0.8 kg·m/69 lb in)
13.Install starter(16) (6VD1).
Torque: 40 N·m (4.1 kg·m/30 lb ft)
14.Install third crossmember(15).
Torque: 50 N·m (5.1 kg·m/37 lb ft)
15.Install engine rear mount nuts(14).
Torque: 40 N·m (4.1 kg·m/30 lb ft)
Remove the transmission jack from transmission
side.
16.Apply grease to top hole portion of the shift fork.
Install slave cylinder(12) and flexible hose fixing
bracket (X22SE).
Torque: 43 N·m (4.4 kg·m/32 lb ft)
220RS007
Legend
(1) Apply Grease
17.Install clutch dust covers(13) to clutch housing
(6VD1).
Torque: 6 N·m (0.6 kg·m/52 lb in)
18.Connect transmission harness connectors and clip.
Connector: transfer switch, 2–4 actuator, car speed
sensor, 1–2 indicator switch (6VD1) and 3–4 indicator
switch (6VD1).
19.Install bracket and transmission harness clamps(10)
to the transmission case.
20.Install harness heat protector(11) (6VD1).
21.Connect fuel pipe to transmission side.
220RW046
220RW047
22.Install center exhaust pipe(9) (6VD1).
Torque: 43 N·m (4.4 kg·m/32 lb ft)
150RX009
23.Tighten the exhaust pipe nuts at the manifold
(X22SE).
Torque: 43 N·m (4.4 kg·m/32 lb ft)
24.Install front(8) and rear propeller shaft(7).
Torque: 63 N·m (6.4 kg·m/46 lb ft)
25.Install transfer protector(6).
Lower the vehicle.
150RX010
26.Install gear control lever(5) and transfer control
lever(5).
27.Install grommet assembly(4).
28.Install center console(3), rear console and lower
cluster assembly.
29.Install transfer control lever knob(2) and gear control
lever knob(1).
30.Connect battery ground cable.
31.Replenish engine coolant (X22SE).
Transmission Case and Transfer Case
Major Component (MUA)
220RX005
Legend
(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Ring
(7) Speedometer Sensor and Speedometer Driven
Gear
(8) Front Companion Flange
(9) Rear Companion Flange
(10) Gear Control Box Assembly
(11) 2WD–4WD Actuator Assembly
(12) Transfer Rear Case Assembly
(13) Detent, Shift Arm, and Interlock Pin
(14) Bearing Snap Ring
(15) Ball Bearing
(16) Lock Nut
(17) High-Low Clutch Hub and Sleeve
(18) Transfer Input Gear
(19) Needle Bearing
(20) Bearing Collar
(21) Ball
(22) Plate
(23) Bearing Snap Ring
(24) Front Output Gear Assembly
(25) Bearing Snap Ring
(26) Counter Gear Assembly
(27) 1–2 and 3–4 Indicator Switch, Pin, and Ball
(28) Transfer Case Assembly
(29) Intermediate Plate with Gear Assembly
(30) Transmission Case
Disassembly
1.Clean the exterior of the unit with solvent.
2.Remove the drain plug from the transmission case
and transfer case and drain the lubricant.
3.Remove the clutch release bearing(1) from the
transmission case.
201RS020
4.Remove the snap pin (6VD1).
Remove the shift fork pin (6VD1) and shift fork(2)
from the fulcrum bridge(3) (6VD1).
201RS021
5.Remove the fulcrum bridge bolts (6VD1).
DRemove the fulcrum bridge(3) (6VD1) from the
transmission case.
Remove the front cover(4) and gasket from the
transmission case.
201RS022
6.Remove counter front bearing snap ring(5) and top
gear bearing snap ring(6).
Use a pair of snap ring pliers to remove the snap ring.
226RS001
7.Remove the speedometer sensor(7).
Remove the plate(7).
Remove the driven gear bushing and driven gear(7).
NOTE: Apply a reference mark to the driven gear bushing
before removal.
8.Remove front companion flange(8) and rear
companion flange(9) using the flange holder
5–8840–0133–0 to remove the end nut.
266RW026
9.Disconnect breather hose from transmission and
remove gear control box assembly(10).
10.Remove 2WD–4WD actuator assembly(11) by
performing the following steps:
1. Disconnect the actuator breather hose from
2WD–4WD actuator assembly(11).
220RW085–1
2. Remove the 2WD–4WD actuator assembly bolts.
3. Pull the 2WD–4WD actuator assembly with
2WD–4WD shift rod.
220RW027
Legend
(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull
(4) Rear Case Assembly
(5) Position: 4WD
(6) Position: 2WD
4. Offset the actuator assembly.
220RW028
5.Remove the actuator assembly.
220RW029
Legend
(7)Position: 4WD
(8)Mode: 2WD
NOTE:Before removing the transmission and transfer
assembly from vehicle, change the transfer mode to 2WD
using the 4WD push button switch on dash panel.
11.Remove the transfer rear cover assembly(12) from
the transfer case(28).
12.Regarding detent, shift arm, and interlock pin(13)
disassembly, refer to Detent, Shift Arm, and Interlock
Pin in Drive Line/Axle section.
13.Use a pair of snap ring pliers to remove the bearing
snap ring(14).
14.Use a bearing remover 5–8840–2155–0 and puller
5–8840–2027–0 to remove the ball bearing(15).
262RW069
15.Install the front companion flange temporarily.
Use the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to remove the lock nut(16).
Remove the front companion flange.
226RW190
16.Remove high-low clutch sleeve(17).
Use the universal puller to remove the high-low clutch
hub(17) and transfer input gear(18).
226RS070
17.Remove needle bearing(19), bearing collar(20),
ball(21), and plate(22).
226RS071
18.Use a pair of snap ring pliers to remove the bearing
snap ring(23).
19.Use a plastic hammer to tap the front output gear
assembly(24) free.
262RS009
20.Remove bearing snap ring(25) by using a pair of snap
ring pliers.
21.Remove the counter gear assembly(26) from the
transfer case(28).
22.Remove 1–2 and 3–4 indicator switch, pin and
ball(27).
23.Remove the transfer case assembly(28) from the
transmission case.
DRefer to Transfer Case Assembly in Drive Line/Axle
section for repair of transfer case assembly.
24.Pull out intermediate plate with gear assembly(29)
from transmission case.
Reassembly
1.Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transmission case(30),
intermediate plate(29) and transfer case(28) fitting
surfaces.
2.Install the intermediate plate with gear assembly(29)
to the transmission case(30).
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 transfer case assembly(28) to the
intermediate plate with gear assembly.
Tighten the eight transmission-transfer case bolts to
the specified torque.
Torque: 37N·m (3.8kg·m/27lbft)
Refer to Transfer Rear Case Assembly in Drive
Line/Axle section for oil seal replacement.
4.Install 1–2 and 3–4 indicator switch, pin and ball(27)
(6VD1).
5.Install the counter gear assembly(26) to the transfer
case(28).
6.Use a pair of snap ring pliers to install the snap
ring(25) to the transfer case(28).
NOTE:The snap ring must be fully inserted into the
transfer case snap ring groove.
7.Install front output gear assembly(24).
8.Use a pair of snap ring pliers to install the snap ring
(23) to the transfer case(28).
NOTE:The snap ring must be fully inserted into the
transfer case snap ring groove.
9.Install plate(22), ball(21), bearing collar(20), needle
bearing(19), and transfer input gear(18).
10.Install High-low clutch hub and sleeve(17).
The clutch hub face (with the heavy boss) must be
facing the transfer input gear side.
226RW152
11.Install the front companion flange temporarily.
DUse the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to install the lock nut(16).
Torque: 137N·m (14.0kg·m/101lbft)
226RW190
12.Use the punch to stake the lock nut at one spot.
13.Use a suitable drift and hammer to install the ball
bearing(15).
226RS079
14.Use a pair of snap ring pliers to install the bearing
snap ring(14).
15.Regarding detent, shift arm, and interlock pin(13)
assembly, refer to Detent, Shift Arm, and Interlock Pin
in Drive Line/Axle section.
16.Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transfer rear case fitting faces.
220RS017
17.Perform the following steps before fitting the transfer
rear cover(11):
1. Shift the High-Low shift rod to the 4H side.
2. The cut-away portion of select rod head should
align with the rear case hole’s stopper.
230RS002
18.Tighten the eleven transfer rear case bolts to the
specified torque.
Torque: 37 N·m (3.8 kg·m/27 lb ft)
19.Install 2WD–4WD actuator assembly(11) by
performing the following steps.
1. Shift the 2WD–4WD shift rod to the 4WD side.
2. Join the rod grooves of 2WD–4WD actuator
assembly and shift rod.
220RW030
Legend
(11) Shift Rod: 2WD–4WD (Position: 4WD)
(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Case Assembly
3. Push the 2WD–4WD actuator assembly with
2WD–4WD shift rod till the shift rod reaches the
2WD position.
220RW031
Legend
(14) Position: 2WD
(15) Mode: 2WD
4. Tighten the 2WD–4WD actuator bolts to the
specified torque.
Torque: 19 N·m (1.9 kg·m/14 lb ft)
5. Connect the actuator breather hose to actuator.
20.Install a new packing and gear control box
assembly(10).
Install the harness clips and brackets and then tighten
four new gear control box bolts to the specified
torque.
Torque: 20 N·m (2.0 kg·m/14 lb ft)
261RW043
21.Install the rear and front companion flange(9) (8).
Install the O-ring(9).
Use the flange holder J–8614–1 1 to tighten the flange
nuts(9) (8) to the transfer case.
Tighten new transfer flange nuts(9) (8) to the
specified torque.
Rear Companion Flange
Torque: 167 N·m (17.0 kg·m/123 lb ft)
Front Companion Flange
Torque: 137 N·m (14.0 kg·m/101 lb ft)
266RW026
22.Use the punch 5–8840–2293–0 to stake the rear
companion flange nut at two spots.
DStake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
266RW027
266RS003
23.Install the O-ring (4) to the speedometer driven gear
bushing(3).
Install the driven gear to the speedometer driven gear
bushing(3).
Install the speedometer driven gear assembly(7) to
the transfer rear cover.
225RW008
24.Install the plate to the transfer rear cover.
Torque: 15 N·m (1.5 kg·m/11 lb ft)
25.Install the speedometer sensor.
Torque: 27 N·m (2.8 kg·m/20 lb ft)
26.Install top gear bearing snap ring(6) and counter front
bearing snap ring(5).
Use a pair of snap ring pliers to install the snap rings
to the mainshaft and countershaft.
The snap rings must be fully inserted into the bearing
snap ring groove.
27.Install a new packing and front cover (with oil seal) (4)
to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
DAfter cleaning the bolt hole, dry it thoroughly with air.
DAfter cleaning the screw face of a removed bolt or new
one, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six new front cover bolts to the specified
torque.
Torque: 25 N·m (2.5 kg·m/18 lb ft)
28.Install the fulcrum bridge(3) to the transmission case.
Tighten three fulcrum bridge bolts to the specified
torque (6VD1).
Torque: 38 N·m (3.9 kg·m/28 lb ft)
220RS009
29.Apply grease to the pin hole inner circumferences and
thrust surfaces (6VD1).
Attach the shift fork(2) to the fulcrum bridge(3) by
inserting the shift fork pin from the bottom side of the
fulcrum bridge (6VD1).
Install the washer and snap pin (6VD1).
201RS018
30.Apply grease to the areas shown in the figure (6VD1).
201RW017
Install the release bearing(1) to the shift fork(2) in the
proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in the figure (6VD1).
201RS019
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Inter-
lock Pin (MUA)
Disassembled View
220RS010
Legend
(1) Detent Spring Plate and Gasket
(2) Detent Spring
(3) Detent Ball
(4) Spring
(5) Rev–5th Shift Rod
(6) Rev–5th Shift Arm and Reverse Inhibitor
(7) 1st–2nd Shift Rod
(8) 3rd–4th Shift Rod
(9) 3rd–4th Shift Arm
(10) 1st–2nd Shift Arm
(11) Interlock Pin
(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.
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).
DHold a round bar against the shift rod end.
230RS003
DUse a spring pin remover to remove the shift arm
spring pins from the shift arms and the shift rods.
230RS004
DMove the 3rd–4th shift rod forward.
230RS005
DRemove the rev–5th, 1st–2nd and 3rd–4th shifter
rods carefully. Interlock pins are located between
the shifter rods in the intermediate plate.
4.Remove interlock pin(1 1) from intermediate plate and
gear assembly(12).
Inspection and Repair
Make the necessary adjustments, and part replacements
if excessive wear or damage is discovered during
inspection.
Shift Arm Thickness
DUse 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
1st–2nd 9.60–9.85 mm
(0.378–0.388 in)
9
.
0
mm
3rd–4th 9.60–9.80 mm
9.0 mm
(0.354 in)
Rev.5th (0.378–0.386 in)
230RS006
Detent Spring Free Length
DUse a vernier caliper to measure the detent spring
free length.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent Spring Free Length
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)
220RS012
Detent Spring Tension
DUse a spring tester to measure the valve spring
tension.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent Spring Tension
Compressed height Standard
20 mm (0.787 in) 87.2 – 97.1 N
(8.9 – 9.9 kg/
19.6 – 21.8 lb)
220RS013
Reassembly
1.Install 1st–2nd shift arm(10) and 3rd–4th shift arm(9)
to intermediate plate and gear assembly(12).
2.Install 3rd–4th shift rod(8) and 1st–2nd shift rod(7).
DInstall the interlock pin(11) to the shift rod.
DInstall the shift rod together with the interlock pin to
the intermediate plate.
Do not allow the interlock pin to fall from the shift
rod.
DHold a round bar against the shift rod end lower face
to protect it against damage.
DInstall a new spring pin.
Never reinstall the used spring pin.
230RS007
3.Install rev–5th shift arm and reverse inhibitor(6) and
rev–5th shift rod(5).
DApply oil to the reverse inhibitor inner surface.
DInstall the interlock pin(11) to the shift rod.
DInstall the shift rod together with the interlock pin to
the intermediate plate.
Do not allow the interlock pin to fall from the shift
rod.
DHold a round bar against the shift rod end lower face
to protect it against damage.
DInstall a new spring pin.
Never reinstall the used spring pin.
4.Install spring(4).
5.Put detent balls(3) in the intermediate plate holes.
DApply oil to the detent balls.
6.Install detent springs(2) and detent spring plate and
gasket(1).
DInstall a new gasket and the detent spring plate.
DTighten the detent spring plate bolts to the specified
torque.
Torque: 20 N·m (2.0 kg·m/ 14 lb ft)
220RS030
Legend
(1) Warped
Reverse Gear and 5th Gear (MUA)
Disassembled View
226RW213
Legend
(1) Oil Seal Collar
(2) Ball Bearing
(3) Retainer
(4) Thrust Plate
(5) Thrust Washer and Lock Ball
(6) Reverse Idler Gear Snap Ring
(7) Reverse Idler Gear Assembly
(8) Idle Shaft Pin
(9) Thrust Washer
(10) Reverse Idler Gear
(11) Reverse Idler Shaft
(12) Bearing Snap Ring
(13) Ball Bearing
(14) Counter 5th Gear
(15) Counter Reverse Gear
(16) 5th Gear
(17) 5th Block Ring
(18) Needle Bearing
(19) Mainshaft Nut
(20) Rev–5th Synchronizer Assembly
(21) Reverse Block Ring
(22) Reverse Gear
(23) Needle Baring
(24) Bearing Plate and Screw
(25) Bearing Snap Ring
(26) Intermediate Plate
Disassembly
1.Set the retaining ring remover 5–8840–2158–0 and
puller 5–8840–2027–0 to the retainer(3) and the
mainshaft end.
262RW079
2.Remove the retainer(3) together with the bearing(2)
and the oil seal collar(1).
The universal puller may be used in place of the
retaining ring remover.
3.Remove thrust plate(4) and thrust washer and lock
ball(5).
4.Use a pair of snap ring pliers to remove reverse idler
gear snap ring(6).
226RS004
5.Remove the reverse idler gear assembly(7) from the
intermediate plate(26).
226RS005
6.Remove idle shaft pin(8), thrust washer(9), reverse
idler gear(10), and reverse idler shaft(11).
7. Use a pair of snap ring pliers to remove the snap
ring(12).
8.Attach the bearing remover to the counter gear shaft.
Use the bearing remover to remove the ball
bearing(13) and the counter 5th gear(14).
226RS006
9.Remove counter reverse gear(15).
10.Remove 5th gear(16), 5th block ring(17), and needle
bearing (2 piece type) (18).
226RS007
11.Attach the holding fixture 5–8840–2160–0 and base
5–8840–0003–0 to the mainshaft and the counter
gear.
226RW212
12.Engage the 3rd–4th synchronizer with the 3rd gear.
Engage the 1st–2nd synchronizer with the 1st gear.
226RW210
Use the mainshaft nut wrench 5–8840–2156–0 to
remove the mainshaft nut(19).
226RW211
13.Use pry bars between the reverse gear(22) and
bearing plate(24) to remove the Rev–5th
synchronizer assembly(20) together with reverse
block ring(21) and reverse gear(22).
226RS010
14.Remove needle bearing(23).
15.Use the torx bit wrench 5–8840–0047–0(T45) to
remove the bearing plate and screw(24) from the
intermediate plate.
220RW137
16.Use the snap ring pliers(1) to remove the mainshaft
bearing snap ring(29).
226RS011
17.Hold the snap ring open with the pliers.
Push the intermediate plate(26) toward the rear of the
transmission to remove it.
The bearing snap ring(25) will come free.
Inspection and Repair
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.
Install the holding fixture 5–8840–2160–0 and base
5–8840–0003–0 to the mainshaft and the counter
gear.
226RW212
2.Place the holding fixture (with the mainshaft and the
counter shaft) in a vise.
Install the intermediate plate(26).
3.Install bearing snap ring(25).
4.Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw(24).
Tighten the screws to the specified torque by using
torx bit wrench 5–8840–0047–0.
Torque: 15 N·m (1.5 kg·m/11 lb ft)
220RW137
5.Install needle bearing(23), reverse gear(22), and
reverse block ring(21).
6.Assemble rev–5th synchronizer assembly(20) by
performing the following steps.
1. Turn the clutch hub face(1) toward the sleeve
groove(2) (rear side) on the outer circumference.
2. Check that the inserts(3) fit snugly into the block
ring insert grooves.
3. Check that the inserts springs(4) are fitted to 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(20) to the
mainshaft.
The clutch hub face (with the heavy boss) must be
facing the reverse gear(22) side.
226RS013
226RS049
7. Mesh the 1st–2nd and 3rd–4th synchronizers with
both the 1st and 3rd gears (double engagement).
226RS015
This will prevent the mainshaft from turning.
8.Install the new mainshaft hub nut(19).
Use the mainshaft nut wrench 5–8840–2156–0 to
tighten the mainshaft nut(19) to the specified torque.
Torque: 137 N·m (14.0 kg·m/101 lb ft)
226RW214
9.Use a punch to stake the mainshaft nut at one spot.
226RW153
10.Install needle bearing(18), 5th block ring(17), and 5th
gear(16).
11.Apply engine oil to the counter reverse gear(15) and
the reverse gear(22).
Install the counter reverse gear(15) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.
226RW151
12.Install the counter 5th gear(14) to the transmission.
226RS019
13.Install ball bearing(13) and bearing snap ring by
performing the following steps:
DSelect the snap ring(12) which will provide the
minimum clearance between the ball bearing and
the snap ring.
226RS020
DThere are six snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.
226RS021
Ball Bearing and Snap Ring Clearance
Standard: 0–0.15 mm (0–0.0059 in)
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
DUse a pair of snap ring pliers to install the snap
ring(12) to the counter gear shaft.
The snap ring must be fully inserted into the counter
gear shaft snap ring groove.
14.Assemble reverse idler shaft(11), reverse idler
gear(10), thrust washer(9), and idle shaft pin(8) into
reverse idler gear assembly(7).
15.Select reverse idler gear snap ring(6) which will
provide the minimum clearance between the
intermediate plate(26) and the snap ring(6).
226RS022
DThere 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)
Snap Ring Availability
Thickness Color Coding
1.2 mm (0.047 in) White
1.3 mm (0.051 in) Yellow
1.4 mm (0.055 in) Blue
226RS021
DUse a pair of snap ring pliers to install the snap ring
to the reverse idler shaft.
The snap ring must be fully inserted into the reverse
idler shaft snap ring groove.
16.Install thrust washer and lock ball(5) by performing
the following steps:
DUse 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)
DMeasure clearance “A” as shown in the figure.
226RS023
DSelect appropriate thrust washer from chart.
DThere are four thrust washer sizes available.
DThe thrust washers are color coded to indicate their
thickness.
Thrust Washer Availability
Thickness
mm (in) Color
Coding A mm (in) Clearance
mm (in)
7.9 (0.311) White 8.05–8.1
(0.317–0.319) 0.15–0.25
(0.006–0.010)
8.0 (0.315) Yellow 8.1–8.2
(0.319–0.323) 0.1–0.25
(0.004–0.010)
8.1 (0.319) Green 8.2–8.3
(0.323–0.327) 0.1–0.25
(0.004–0.010)
8.2 (0.323) Bluen 8.3–8.36
(0.327–0.329) 0.1–0.21
(0.004–0.008)
226RS024
DApply grease to the thrust washer and the lock ball.
DInstall the thrust washer and the lock ball.
17.Install thrust plate(4) and retainer(3).
18.Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5–8840–2159–0 to install the ball
bearing(2) to the mainshaft in proper direction.
226RW215
19.Install oil seal collar(1).
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)
Disassmebled View
226RS026
Legend
(1) Top Gear Shaft Snap Ring
(2) Top Gear Shaft
(3) Ball Bearing
(4) Needle Bearing
(5) Top Block Ring
(6) Mainshaft Snap Ring
(7) 3rd–4th Synchronizer Assembly
(8) 3rd Block Ring
(9) 3rd Gear
(10) Needle Bearing
(11) Needle Bearing Collar
(12) Mainshaft Ball Bearing
(13) 1st Gear Thrust Bearing
(14) 1st Gear
(15) 1st Inside Ring
(16) 1st Outside Ring
(17) 1st Block Ring
(18) Needle Bearing
(19) Clutch Hub Snap Ring
(20) 1st–2nd Synchronizer Assembly
(21) 2nd Block Ring
(22) 2nd Outside Ring
(23) 2nd Inside Ring
(24) 2nd Gear
(25) Needle Bearing
(26) Mainshaft
(27) Bearing Snap Ring
(28) Front Rollar Bearing
(29) Center Roller Bearing
(30) Counter Gear Shaft
Disassembly
1.Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2.Remove top gear shaft(2) with ball bearing(3).
3.Use a bench press and the bearing remover
5–8840–0015–0 to remove the ball bearing(3).
226RW216
4.Remove needle bearing(4) and top block ring(5),
mainshaft snap ring.
5.Use a pair of snap ring pliers to remove the mainshaft
snap ring(6).
226RS028
6.Use a bench press and the bearing remover
5–8840–0015–0 to remove the 3rd–4th synchronizer
assembly(7) as a set.
Disassemble the synchronizer assembly.
226RW217
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7.Remove 3rd block ring(8), 3rd gear(9), and needle
bearing(10).
8.Remove needle bearing collar(11).
9.Use a bench press and the bearing remover
5–8840–0015–0 to remove the 1st gear(14) together
with the mainshaft ball bearing(12) and 1st gear thrust
bearing(13).
226RW218
10.Disassemble 1st inside ring(15), 1st outside ring(16),
and 1st block ring(17).
11.Remove needle bearing(18).
12.Use a pair of snap ring pliers to remove the clutch hub
snap ring(19).
226RS031
13.Use a 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 2nd inside
ring(23).
Disassemble the synchronizer assembly.
226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
14.Remove needle bearing(25) from mainshaft(26).
15.Remove bearing snap ring(27)
16.Use a bench press and the bearing remover
5–8840–0015–0 to remove the front roller
bearing(28).
226RW219
17.Remove center roller bearing(29) from counter gear
shaft(30).
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Block Ring and Dog Teeth Clearance
DUse 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.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
1st–2nd Synchronizer (3–CONE)
DUse a thickness gauge to measure the clearance
between the block ring and the dog teeth.
226RS036
If the measured value exceeds the specified limit,the
1st–2nd synchronizer assembly must be replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance
DUse a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.
226RS037
If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block and Insert Clearance
Standard Limit
3rd–4th 3.46 – 3.74 mm
(0.136 – 0.147 in) 4.0 mm
(0.158 in)
1st–2nd 4.34 – 4.66 mm
(0.171 – 0.183 in) 4.9 mm
(0.193 in)
Rev–5th 3.59 – 3.91 mm
(0.141 – 0.154 in) 4.1 mm
(0.161 in)
Clutch Hub and Insert Clearance
DUse a thickness gauge to measure the clearance
between the clutch hub and the insert.
226RS038
If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance
Standard Limit
3rd–4th 0.01 – 0.19 mm
(0.0004 – 0.0075 in) 0.3 mm
(0.012 in)
1st–2nd 0.09 – 0.31 mm 0.4 mm
Rev–5th (0.0035 – 0.0122 in) (0.016 in)
Mainshaft Run-out
DInstall the mainshaft to V-blocks.
DUse a dial indicator to measure the mainshaft central
portion run-out.
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
DUse an inside dial indicator to measure the gear inside
diameter.
226RS040
If the measured value is less than the specified limit,
the gear must be replace.
Gear Inside Diameter
Standard Limit
1st 45.000 – 45.013 mm 45.100 mm
3rd (1.771 – 1.772 in) (1.776 in)
2nd 52.000 – 52.013 mm
(2.047 – 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 – 48.013 mm
(1.889 – 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 – 32.013 mm
(1.259 – 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
DUse a micrometer to measure the idler gear shaft
diameter.
DUse an inside dial indicator to measure the idler gear
inside diameter.
226RS041
DCalculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, 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 (0.016–0.0029 in)
Limit: 0.150 mm (0.0059 in)
Clutch Hub Spline Play
DSet a dial indicator to the clutch hub to be measured.
226RS042
DMove the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st–2nd 0 – 0.1 mm 0.2 mm
3rd–4th (0 – 0.004 in) (0.008 in)
Rev. 5th 0 – 0.2 mm
(0 – 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
DUse a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS043
Reassembly
1.Install center roller bearing(29) to counter gear
shaft(30).
DApply engine oil to the bearing inner and outer
circumferences.
DInstall the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the direction
of arrow.
226RS044
2.Install front roller bearing(28) by performing the
following steps.
DUse bearing installer to install the front roller
bearing inner race to the counter gear shaft.
DInstall the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
DUse bearing installer J–35283 to install the ring.
226RS045
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3.Install bearing snap ring(27) to mainshaft(26).
4.Apply engine oil to the needle bearing(25) and the 2nd
gear thrust surfaces.
Install the needle bearing(25) and the 2nd gear(24) to
the mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.
226RS046
5.Assemble 2nd inside ring(23), 2nd outside ring(22),
and 2nd block ring(21).
DApply engine oil to the synchronizer ring friction
surfaces.
226RS047
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6.Assemble 1st–2nd synchronizer assembly by
performing the following steps:
1. Check that the inserts(3) fit snugly into the block
ring insert grooves.
2. Check that the inserts springs(4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub(5) and the sleeve(6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.
226RS048
226RS049
7.Install clutch hub snap ring(19) by performing the
following steps:
DSelect the snap ring which will provide the minimum
clearance between the 1st–2nd clutch hub and the
snap ring.
226RS050
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness.
226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 – 0.1 mm (0 – 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
DUse a pair of snap ring pliers to install the snap ring
to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
226RS031
8.Install needle bearing(18), 1st block ring(17), 1st
outside ring(16), 1st inside ring(15), and 1st gear(14).
DApply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
DInstall the needle bearing and the 1st gear to the
mainshaft.
The 1st gear dog teeth must be facing the
transmission front side.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
9.Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
transmission front side.
226RS054
10.Apply engine oil to the mainshaft ball bearing(12) and
the mainshaft(26).
Install the ball bearing(12) and needle bearing
collar(11) to the mainshaft(26).
The ball bearing snap ring groove must be facing the
transmission rear side.
Use a bench press and installer J–6133–01 to slowly
force the collar into place.
226RS055
11.Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing(10) and the 3rd gear(9) to
the mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.
226RS056
12.Install 3rd block ring(8).
13.Check and install 3rd–4th synchronizer assembly(7)
by the following steps:
1. Check that the inserts(3) fit snugly into the block
ring insert grooves.
2. Check that the insert springs(4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub(5) and the sleeve(6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face (with the heavy boss) must be
facing the 3rd gear side.
226RW221–1
226RS049
14.Select and install mainshaft snap ring(6) in the
following way:
DSelect the snap ring which will provide the minimum
clearance between the 3rd–4th clutch hub and the
snap ring.
226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness.
226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 – 0.1 mm (0 – 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
DUse a pair of snap ring pliers to install the snap ring
to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
15.Install top block ring(5).
16.Apply grease to the bearing inner and outer
circumferences and install needle bearing(4).
17.Use a bench press to install the top gear shaft ball
bearing(3) to the top gear shaft(2).
226RS059
The snap ring groove must be facing the transmission
front side.
18.Use a pair of snap ring pliers to install the top gear
shaft snap ring(1) to the bearing.
Main Data and Specifications
General Specifications
MUA 5C Manual Transmission 5 Speed
4X4
Transmission type Fully synchronized forward and reverse gears
Transfer case Synchronized type gears shifting between the 2– and
4–wheel drive mode.
Constant mesh type gears between “low” and “high”
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 3.767
2nd 2.248
3rd 1.404
4th 1.000
5th 0.809
Rev. 3.873
Gear ratio: Transfer High 1.000
Low 2.050
Transmission oil capacity 2.95 lit. (3.12 US qt)
Transfer oil capacity 1.45 lit. (1.53 US qt)
Type of lubricant Engine oil: Refer to the chart in “SECTION 0”
Torque Specifications (Cont’d)
E07RX014
Torque Specifications (Cont’d)
E07RX013
Special Tools (MUA)
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2158–0
Mainshaft collar remover
5–8840–2027–0
Puller
5–8840–2160–0
Holding fixture
5–8840–0003–0
Holding fixture base
5–8840–2156–0
Wrench
5–8840–0047–0
Tork bit wrench
(T–45)
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2159–0
Mainshaft end bearing
installer
5–8840–0015–0
Bearing
remover/installer
5–8840–0026–0
Front cover oil seal
installer
9–8522–1165–0
Mainshaft collar installer
5–8840–2291–0
Remover; Clutch release
bearing
5–8840–0133–0
Flange holder
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2293–0
Punch; end nut
5–8840–2194–0
Counter shaft bearing
installer
5–8840–2155–0
Bearing remover