SECTION 7B - MANUAL TRANSMISSION -
4X2 (MUA5C & MUA5S)
4 ×
××
× 2 MODEL TRANSMISSION
MAIN DATA AND SPECIFICATIONS
GENERAL DESCRIP TION
TORQUE SPECIFICATIONS
STANDARD BOLTS
FLARE NUTS
SPECIAL PARTS FIXING NUTS AND BOLTS
RECOMMENDED LIQUID GASKET
REMOVAL AND INSTALLATION
DISASSEMBLY
MAJOR COMPONENTS
MINOR COMPONENTS
INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY,
AND INTERLOCK PIN
REVERSE GEAR AND 5TH GEAR
TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR
INSPECTION AND REPAIR
REASSEMBLY
MINOR COMPONENTS
TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR
REVERSE GEAR AND 5TH GEAR
INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY,
AND INTERLOCK PIN
MAJOR COMPONENTS
4 ×
××
× 2 MODEL TRANSMISSION
MAI N DATA AND SPECIFICATI ONS
Models MUA 5C MUA 5S
Transmission type Fully synchronised 5-forward and revers gears.
Gear ratio 1st
2nd
3rd
4th
5th
Rev.
3.767
2.248
1.404
1.000
0.809
3.873
4.357
2.502
1.501
1.000
0.809
3.970
Oil capacity litres 2.95
GENERAL DESCRI PTION
Principle parts of the transmission are the integral clutch housing, the intermediate plate, the rear cover, and the gears.
The gear control box is built-in to the rear cover.
TORQUE SPECIFICATIONS
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.
N⋅m (kgf⋅m/lb⋅ft)
Strength 4.8/4T 7T 8.8 9.8/9T
Class Refined Non-Refined
Bolt Identifi-
cation
Bolt
Diameter×
××
×
Pitch (mm) No mark -
M6 × 1. 0 6 (0.6 / 52 lb.in) 7 (0.7 / 61 lb. i n) 8 (0.8 / 69 lb. i n) -
M8 × 1. 25 13 (1.3 / 113
lb.in) 17 (1.7 / 12) 20 (2.0 / 14) 24 (2.4 / 17)
M10 × 1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)
M12 × 1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 / 64) 95 (9.7 / 70)
M14 ×1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)
M16 × 1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)
M18 × 1.5 188 (19.2 / 139) 244 (24.9 / 180) 278 (28.3 / 205) 287 (29.3 / 212)
M20 × 1.5 258 (26.3 / 190) 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)
M22 × 1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)
M24 × 2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)
*M10 × 1. 5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)
*M12 × 1. 75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9. 1 / 66)
*M14 × 2. 0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)
*M16 × 2. 0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)
Flange Bolt M6 × 1. 0 7 (0.7 / 61 lb.in) 8 (0.8 / 69 lb. i n) 9 (0.9 / 78 lb. i n) -
M8 × 1. 25 15 (1.5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2.7 / 20)
M10 × 1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)
M12 × 1.25 69 (7.0 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)
M14 × 1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (15. 7 / 114)
M16 × 1.5 145 (14.8 / 127) 188 (19.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)
M18 × 1.5 - - - -
M20 × 1.5 - - - -
M22 × 1.5 - - - -
M24 × 2.0 - - - -
*M10 × 1. 5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)
*M12 × 1. 75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)
*M14 × 2. 0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)
*M16 × 2. 0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 152) 210 (21.5 / 155)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as
casting, etc.
FLARE NUTS
Pipe diameter mm (in) Torque N⋅
⋅⋅⋅m (kgf⋅
⋅⋅⋅m / lb⋅
⋅⋅⋅ft) Pipe diameter mm (in) Torque N⋅
⋅⋅⋅m (kgf⋅
⋅⋅⋅m / lb⋅
⋅⋅⋅ft)
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)
6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)
Standard Hex.
Head Bolt
SPECIAL PARTS FI XI NG NUTS AND BOLTS
N⋅m (kgf⋅m/lb⋅ft)
39.2±9.8
(4.0±1.0/28.9±7.2)
15 (1.5/11)
137±20
(14±2/101±14.4)
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacturer Remarks
ThreeBond 1207B Three Bond
RTV* ThreeBond 1207C Three Bond
Silicon Base ThreeBond 1215 Three Bond For Axle Case and
ThreeBond 1281 Three Bond Transmission Repairs
Water Base ThreeBond 1141E Three Bond For Engine Repairs
ThreeBond 1104 Three Bond
BelcoBond 4 Isuzu
BelcoBond 401 Isuzu
BelcoBond 402 Isuzu
LOCTITE 515 Loctite
LOCTITE 518 Loctite
*RTV: Room Temperature Vulcanizer
Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent is used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the
liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTIT E 518 between tw o metal surfaces having a clearance of greater than
0.25 mm (0.01 in). Poor adhesion will result.
For Engine Repairs
For Engine Repairs
Solvent
AllAnerobic
REMO VAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you important
points as well as the order of operation. Be sure that you understand everything in this Section before you begin.
IMPO RTANT OPERATIONS-REMOVAL
Battery Cable
Disconnect the negative (-) cable from the battery terminal.
Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.
Gear Shift Lever
1. Place the gearshift lever in the neutral position.
2. Remove the gearshift lever knob.
3. Remove the front console assembly.
4. Remove the gearshift lever grommet and dust cover.
5. Remove the gearshift lever cover bolts.
6. Remove the gearshift lever.
Note:
Cover the shift lever hole to prevent the entry of for eign
material into the transmission.
Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the vehicle.
Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.
Exhaus t Pipe
1. Remove the exhaust pipe bracket form the transmission
case.
2. Remove the front exhaust pipe and 2nd-3rd exhaust pipe.
Rear Propeller Shaft (Single Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion
side 1.
2. Remove the propeller shaft from the transmission main
shaft spline 2.
Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent misaligning during the installation procedure.
2. Remove the 2nd propeller shaft flange yoke bolts at the
drive pinion side 1.
3. Remove the centre bearing retainer bolts 2.
4. Remove the 1st propeller shaft 3 with the centre bearing
and the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle
unit the spline yoke is free of the transmission main shaft.
Harness Connector
Disconnect the back up light switch connector and the
speedometer sensor connector.
Slave Cylinder
Remove the slave cylinder from the transmission case.
Engine Lifting Hanger
1. Attach the engine-lifting hanger to the front portion of the
engine.
2. Attach the lifting wire to both ends of the engine-lifting
hanger.
Starter Motor
Remove the starter motor from the engine.
Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine r ear mounting bracket bolts and nuts 1
from the transmission 2.
3. Remove bracket from the No.3 crossmember.
4. Loosen nuts for the rear mounting rubber.
5. Remove the rear mounting rubber 3 from transmission.
6. Remove the gear control box from the transmission.
7. Remove the transmission from the engine.
The r emoval of the tr ans miss ion will requir e the c ooper ative
efforts of two mechanics.
1) Remove the transmission nuts and bolts 1 from the
engine rear plate.
2) Place a transmission jack 2 beneath the transmission.
Do not raise the transmission jack.
3) Manually move the transmission as far as possible
toward the rear of the vehicle (into the space between
the No.3 crossmember 3 and the floor panel 4.
4) Lower the c lutch housing end of the transm iss ion toward
the transmission jack.
The rear of the transmission is supported by the No.3
crossmember at this time.
5) Firmly grasp the transmission rear cover (1st mechanic).
Raise the transmission jack toward the transmission
(2nd mechanic).
Carefully lower the transmission onto the transmission
jack.
The transmission must be centred on the transmission
jack.
8. Carefully pull the transmission jack with the transmission
from beneath the vehicle.
IMPORTANT OPERATIONS-INSTALLATION
Follow the removal procedure in the reverse order to perform
the installation procedure. Pay careful attention to the
important points during the installation procedure.
TRANSMISSION
1. Apply a thin c oat of m olybdenum disulf ide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into
position behind the engine.
4. Slowly operate the transmission jack to raise the
transmission until the rear of the transmission is at the
same level as the No.3 crossmember 1.
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3
crossmember and the floor panel 2.
6. Slowly raise the transmission jack until the front of the
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be the
same.
7. Install the gear control box to the transmission.
8. Install the rear mounting rubber 3 to the transmission 2.
Install the rear mounting rubber 3 to the No.3
crossmember 4.
9. Tighten the rear mounting rubber nuts 1 to the specified
torque.
Rear Mounting Rubber Nut Torque N⋅m (kgf⋅m/lb⋅ft)
41 ± 4.9 (4.2 ± 0.5 / 30 ± 3.6)
Mounting Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
50 ± 6 (5.1 ± 0.6 / 37 ± 4.3)
STARTER M OTOR
1. Install the starter motor to the engine.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
78 ± 16 (8.0 ± 1.6 / 58 ± 12)
SLAVE CYLINDER
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
40 ± 10 (4.1 ± 1.0 / 30 ±7.2)
Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.
REAR PROPELLER SHAFT ( SINGLE SHAFT TYPE)
1. Insert the splined yoke 1 with the propeller shaft into the
transmission main shaft spline 2.
2. Install the propeller shaft flange yoke 3 to the drive pinion
side.
3. Tighten the propeller shaft flange yoke bolt to the specified
torque.
Propeller Shaft Flange Yoke Bolt Torque
6.4 ± 0.4 (46.3 ± 2.9 / 62.7 ± 3.9)
REAR PROPELLER SHAFT ( DUAL SHAFT TYPE)
1. Place the centre bearing and retainer 1 together with the
1st propeller s haft 2 and 2nd propeller s haft 7 on the No.4
crossmember 3.
2. Insert the splined yoke 4 into the transmission main shaft
spline 5.
3. Tighten the centre bearing retainer bolts 6 to the specified
torque.
Centre Bearing Retainer Bolt Torque N⋅m (kgf⋅m/lb⋅ft
)
60.8 ± 11.8 (6.2 ± 1.2 / 44.8 ± 8.7)
4. Connect the 2nd propeller shaft 7 and drive pinion side 8.
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque N⋅m (k gf⋅m/lb⋅ft)
62.7 ± 3.9 (6.4 ± 0.4 / 46.3 ± 2.9)
Exhaus t Pipe
1. Install the front exhaust pipe and 2nd-3rd exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.
GEAR SHI FT LEVER
1. Replenish the transmission case with the specified engine
oil.
Transmission Case Oil lit (US/UK pt.)
2.95 (3.12 / 2.6)
2. Install the gearshift lever to the gear control box.
3. Tighten the gearshift lever cover bolts to the specified
torque.
Shift Lever Cover Bolt Torque N⋅m (kg f⋅m/lb⋅ft)
19.6 ± 1.96 (2.0 ± 0.2 / 14.5 ± 1.5)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gearshift lever knob.
Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.
Engine Hood
Align the setting marks (applied at removal) on the engine
hood and the engine hood hinges to install the engine hood.
Battery Cable
Connect the negative (-) cable to the battery terminal.
DISASSEMBLY
MAJO R COMPONENTS
DISASSEM BLY STEPS
▲1. Speedometer driven gear and
speedometer sensor
2. Gear control box assembly
▲3. Front cover with oil seal
▲4. Counter front bearing snap ring
▲5. Front bearing snap ring
6. Rear cover with oil seal
7. Transmission case
8. Intermediate plate with gear assembly
IMPORTANT OPERATIONS
1. Speedometer Sensor and Speedometer Driven Gear
Mark the plate 1 and bush 2 alignment for reassembly.
3. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission
case.
4. Counter Front Bearing Snap Ring
5. Front Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
MINOR COMPONENTS
INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT,
SHIFT ARM ASSEMBLY, AND INTERLOCK PI N
DISASSEM BLY STEPS
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
IMPORTANT OPERATIONS
3.Detent Ball
Use a magnetic hand to remove the detent balls from the
intermediate plate.
Take care not to lose the detent balls.
8.3rd-4th Shift Rod
9.3rd-4th Shift Arm
10.1st-2nd Shift Arm
1) Hold a round bar against the shift arm end.
This will prevent damage to other components.
2) Use a s pring pin remover to r em ove the shif t arm spr ing pin
from the shift arm and the shift rod.
3) Move the 3rd-4th shift rod forward.
Take care not to lose the interlock pins.
REVERSE GEAR AND 5TH G EAR
DISASSEM BLY STEPS
1. Bearing snap ring
2. Bearing snap ring
▲3. Ball bearing
4. Clip
5. Speedometer drive gear
6. Retainer snap ring
7. Retaining ring
8. Thrust plate
9. Thrust washer and lock ball
▲10. Reverse gear snap ring
11. Reverse shaft
12. Idler shaft pin
13. Thrust washer
14. Reverse idler gear
15. Bearing snap ring
▲16. Ball bearing
▲17. Counter 5th gear
18. Counter reverse gear
19. 5th gear
20. 5th block ring
▲21. Needle bearing
▲22. Mainshaft nut
▲23. Rev-5th synchroniser assembly
▲24. Reverse block ring
▲25. Reverse gear
26. Needle bearing
▲27. Bearing plate and screw
▲28. Bearing snap ring
▲29. Intermediate plate
IMPORTANT OPERATIONS
3.Ball Bearing
Set the bearing remover to the bearing and the mainshaft end
to remove the bearing.
Bearing Remover : 5-8840-2155-0 (J-32717)
Puller : 5-8840-2027-0
10.Reverse Gear Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
16.Ball Bearing
17.Counter 5th Gear
Use the bearing remover to remove the bearing.
21.Needle Bearing
Remove the needle bearing (2 piece type).
22.Mainshaft Nut
1) Engage the 3rd-4th synchroniser with the 3rd gear.
2) Engage the 1st-2nd synchroniser with the 1st gear.
3)
A
ttach the holding fixture to the mainshaft and the counte
r
gear.
Holding Fixture: 5-8840-2160-0 (J-37224)
4) Use the mainshaft nut wrench to remove the mainshaft nut.
Wrench: 5-8840-2156-0 (J-37219)
23.Rev.-5th Synchroniser Assembly
24.Reverse Ring
25.Reverse Gear
Use screw drivers between the reverse gear and bearing plate
to remove the Rev.-5th synchroniser assembly together with
reverse ring and gear.
27.Bearing Plate and Screw
Use the Torx bit wrench to remove the bearing plate screw
from the intermediate plate.
Torx Bit Wrench: 5-8840-0047-0 (J-37225: T45)
28.Bearing Snap Ring
29.Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap
ring hole.
2) Use the snap ring pliers 1 to force open the mainshaft
bearing snap ring 2.
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the
transmission to remove it.
The ball bearing snap ring will come free.
TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR
DISASSEM BLY STEPS
1. Top gear shaft snap ring
2. Top gear shaft
▲3. Top gear ball bearing
4. Needle bearing
5. Top block ring
▲6. Mainshaft snap ring
▲7. 3rd-4th synchroniser assembly
8. 3rd block ring
9. 3rd gear
10. Needle bearing
▲11. Needle bearing collar
▲12. Mainshaft ball bearing
▲13. 1st gear thrust bearing and plate
▲14. 1st gear
15. 1st block ring (set)
16. Needle bearing
▲17. Clutch hub snap ring
▲18. 1st-2nd synchroniser assembly
▲19. 2nd block ring (set)
▲20. 2nd gear
21. Needle bearing
22. Mainshaft
23. Bearing snap ring
▲24. Counter gear front bearing
25. Counter gear centre bearing
26. Counter gear
IMPORTANT OPERATIONS
3. Top Gear Ball Bearing
Use a bench press and the bearing replacer to remove the ball
bearing.
Bearing Replacer: 5-8840-0015-0 (J-22912-01)
6.Mainshaft Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
7.3rd-4th Synchroniser Assembly
1) Use a bench press and the bearing replacer to remove the
synchroniser assembly as a set.
2) Disassemble the synchroniser assembly.
1Springs
2Sleeve
3Clutch Hub
4Inserts
Note:
Mark the hub and sleeve alignment for reassembly.
11.Needle Bearing Collar
12.Mainshaft Ball Bearing
13.1st Gear Thrust Bearing and Plate
14.1st Gear
Use a bench press and the bearing replacer to remove the ball
bearing.
17.Clutch Hub Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
18.1st-2nd Synchroniser Assembly
19.2nd Block Ring (Set)
20.2nd Gear
1) Use a bench press and the bearing remover to remove the
2nd gear together with synchroniser assembly.
Remover: 5-8840-0015-0 (J-22912-01)
2) Disassemble the synchroniser assembly.
1Springs
2Sleeve
3Clutch Hub
4Inserts
Note:
Mark the hub and sleeve alignment for reassembly.
24.Counter Gear Front Bearing
Use a bench press and the bearing remover to remove the
bearing.
Bearing Remover: 5-8840-0015-0 (J-22912-01)
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, 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 mm (in)
Standard Limit
1st-2nd 9.60-9.85 (0.378-0.388)
3rd-4th
Rev.-5th 9.60-9.80 (0.378-0.386) 9.0 (0.354)
DETENT SPRING FREE LENGTH
Use 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 mm (in)
Standard Limit
26.8 (1.06) 26.2 (1.03)
DETENT SPRING TENSION
Use a spring tester to measure the detent spring tension.
If the measured value is less than the specified standard, the
detent spring must be replaced.
Detent Spring Tension N (kg/lb)
Compressed Height Standard
20 mm (0.787 in) 87.2-97
(8.9-9.9 / 19.6-21.8)
BLOCK RING AND DOG TEETH CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance mm (in)
Standard Limit
1.5 (0.059) 0.8 (0.032)
BLOCK RING AND INSERT CLEARANCE
Use a vernier caliper or thickness gauge to measure the
clearance between the block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance mm (in)
Standard Limit
3rd-4th 3.46-3.74 (0.136-0.147) 4.0 (0.158)
1st-2nd 4.34-4.66 (0.171-0.183) 4.9 (0.193)
Rev.-5th 3.59-3.91 (0.141-0.154) 4.1 (0.161)
CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance mm (in)
Standard Limit
3rd-4th 0.01-0.19 (0.0004-0.0075)
1st-2nd
Rev.-5th 0.09-0.31 (0.0035-0.0122) 0.4 (0.016)
MAI NSHAFT RUN-OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central
portion run-out.
If the measured mainshaft run-out exceeds the specified
limit, the mainshaft must be replaced.
Mainshaft Run out mm (in)
Limit
0.05 (0.0020)
GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter mm (in)
Standard Limit
1st
3rd 45.000-45.013
(1.771-1.772) 45.100 (1.776)
2nd 52.000-52.013
(2.047-2.048) 52.100 (2.051)
Rev. 48.000-48.013
(1.889-1.890) 48.100 (1.894)
5th 32.000-32.013
(1.259-1.260) 32.100 (1.264)
REVERSE IDLER GEAR AND IDLER GEAR SHAFT
CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to m easure the idler gear inside
diameter.
3. Calculate the idler gear and idler gear shaft clearance.
Idler gear inside diameter - idler gear shaft diameter = idle
r
gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the idle
r
gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance mm (in)
Standard Limit
0.041-0.074 (0.0016-0.0029) 0.150 (0.0059)
CLUTCH HUB SPLINE PLAY
1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as poss ible to both the right and
the left.
Note the dial indicator reading.
It the meas ur ed value ex ceeds the s pecified lim it, the c lutc h
hub must be replaced.
Clutch Hub Spline Play mm (in)
Standard Limit
1st-2nd
3rd-4th 0-0.1 (0-0.0039) 0.2 (0.0079)
Rev.-5th 0-0.2 (0-0.0079) 0.3 (0.0118)
BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play mm (in)
Limit
0.2 (0.0079)
FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.
OIL SEAL INSTALLATION
1. Use the oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer: 5-8840-0026-0 (J-26540)
2. Apply gear oil to the oil seal lip.
REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.
OIL SEAL INSTALLATION
1. Use the oil seal installer to install the oil seal to the rea
r
cover.
Oil Seal Installer: 5-8522-0050 (J-29769)
2. Apply engine oil to the oil seal lip.
REASSEMBLY
MINOR COMPONENTS
TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR
REASSEMBLY STEPS
1. Mainshaft
▲2. Needle bearing
▲3. 2nd gear
4. 2nd block ring (set)
▲5. 1st-2nd synchroniser assembly
▲6. Clutch hub snap ring
▲7. Needle bearing
8. 1st block ring (set)
▲9. 1st gear
▲10. 1st gear thrust bearing and plate
▲11. Mainshaft ball bearing
▲12. Needle bearing collar
▲13. Needle bearing
▲14. 3rd gear
15. 3rd block ring
▲16. 3rd-4th synchroniser assembly
▲17. Mainshaft snap ring
18. Needle bearing
19. Top block ring
20. Top gear shaft
▲21. Top gear ball bearing
▲22. Top gear shaft snap ring
23. Counter gear
▲24. Counter gear front bearing
25. Snap ring
26. Counter gear centre bearing
IMPORTANT OPERATIONS
2. Needle Bearing
3. 2nd Gear
1)
A
pply engine oil to the needle bearing and the 2nd gea
r
thrust surfaces.
2) Install the needle bearing and the 2nd gear to the
mainshaft.
The 2nd gear dog teeth must be facing the transmission
rear side.
5. 1st-2nd Synchroniser Assembly
1) Turn the clutch hub f ace 1 shallow toward the sleeve s mall
groove 2 on the outer circumference.
Note:
The clutch hub groove
A
must be aligned with the key
groove of sleeve.
2) Check that the inserts 3 fit snugly into the block ring insert
grooves.
3) Check that the insert 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 synchroniser assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing
the 2nd gear side.
6. Clutch Hub Snap Ring
1) Select the snap ring, which will provide the minimum
clearance between the 1st-2nd clutch hub and the snap
ring.
There are three snap ring sizes available.
The snap rings are colour-coded to indicate their thickness.
Clutch Hub and Snap Ring Clearance mm (in)
Standard
0-0.1 (0-0.0039)
Snap Ring Availability mm (in)
Thickness Color-Coding
1.80 (0.071) White
1.85 (0.073) Yellow
1.90 (0.075) Blue
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.
Snap Ring Pliers
The snap ring mus t be f ully inserted into the m ains haf t s nap
ring groove.
7.Needle Bearing
9.1st Gear
1)
A
pply engine oil to the needle bearing and the 1st gea
r
thrust surfaces.
2) Install the needle bearing and the 1st gear to the mainshaft.
The 1st gear dog teeth must be facing the transmission
front side.
10.1st Gear Thrust Bearing and Plate.
Install the thrust bearing and the race to the main shaft.
The thrust bearing side must be facing the transmission front
side.
11.Mainshaft Ball Bearing
12.Needle Bearing Collar
1) Apply engine oil to the ball bearing and the mainshaft.
2) Install the ball bearing and collar to the mainshaft.
The ball bearing snap ring groove must be facing the
transmission rear side.
3) Use a bench press to slowly force the collar into place.
Installer: 5-8840-2195-0 (J-6133-01)
13.Needle Bearing
14.3rd Gear
1)
A
pply engine oil to the needle bearing and the 3rd gea
r
thrust surfaces.
2) Install the needle bearing and the 3rd gear to the mainshaft.
The 3rd gear dog teeth must be facing the transmission
front side.
16.3rd-4th Synchroniser Assembly
1) Turn the clutch hub face 1 with the heavy boss Atoward
the sleeve small groove 2 on the outer circumference.
2) Check that the inserts fit snugly into the block ring insert
grooves.
3) Check that the insert springs are fitted to the inserts as
shown in the illustration.
4) Check that the clutch hub and the sleeve slide smoothly.
5) Install the synchroniser assembly to the main shaft.
The clutch hub face (with the heavy boss) must be facing
the 3rd gear side.
17.Mainshaft Snap Ring
1) Select the snap ring, which will provide the minimum
clearance between the 3rd-4th clutch hub and the snap
ring.
There are three snap ring sizes available.
The snap rings are colour-coded to indicate their thickness.
Clutch Hub and Snap Ring Clearance mm (in)
Standard
0-0.1 (0-0.0039)
Snap Ring Availability mm (in)
Thickness mm (in) Color-Coding
1.80 (0.071) White
1.85 (0.073) Yellow
1.90 (0.075) Blue
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.
The snap ring mus t be f ully inserted into the m ains haf t s nap
ring groove.
21.Top Gear Ball Bearing
22.4th Gear Shaft Snap Ring
1) Use a bench press to install the top gear shaft ball bearing
to the mainshaft.
The snap ring groove m ust be fac ing the transmiss ion front
side.
2) Use a pair of snap ring pliers to install the snap ring to the
bearing.
24.Counter Gear Front Bearing
Use a bench press to install the counter gear front bearing to
the mainshaft.
The snap ring groove must be facing the transmission front
side.
Bearing Installer: 5-8840-2194-0 (J-35283)
1) Apply engine oil to the bearing and install the inner race 1
and outer race with roller 2 in the proper direction to the
mainshaft.
2) Then install the inner rac e 3with taper side turned to oute
r
race 2.
Note:
The inner race 3 should be installed with stamp on die
face side turned to the front side of transmission.
REVERSE GEAR AND 5TH G EAR
REASSEMBLY STEPS
▲1. Intermediate plate
2. Bearing snap ring
▲3. Bearing plate and screw
4. Needle bearing
5. Reverse block ring
6. Reverse gear
▲7. Rev.-5th synchroniser assembly
▲8. Mainshaft nut
9. Needle bearing
10. 5th block ring
11. 5th gear
▲12. Counter reverse gear
13. Counter 5th gear
14. Ball bearing
15. Reverse idler gear
16. Thrust washer
17. Idler shaft pin
18. Reverse idler shaft
▲19. Bearing snap ring
▲20. Reverse gear snap ring
▲21. Thrust washer and lock ball
22. Thrust plate
23. Retaining ring
24. Retainer snap ring
25. Speedometer drive gear
26. Clip
27. Bearing snap ring
▲28. Ball bearing
29. Bearing snap ring
IMPORTANT OPERATIONS
1. Intermediate Plate
1) Mesh the counter gear with the mainshaft assembly.
2) Install the holding fixture to the mainshaft and the counte
r
gear.
Holding Fixture: 5-8840-2160-0 (J-37224)
Holding Base: 5-8840-0003-0 (J-3289-20)
3) Place the holding fixture (with the mainshaft and the
countershaft) in a vice.
4) Install the intermediate plate.
3. Bearing Plate and Screw
1) Apply recom mended thr ead locking agents or its equivalent
to each of the bearing plate screw threads.
2) Tighten the screws to the specified torque.
Torx Bit Wrench: 5-8840-0047-0 (J-37225: T45)
Bearing Plate Screw Torque N⋅m (kgf⋅m/lb⋅ft)
15 (1.5 / 11)
7. Rev-5th Synchroniser A ssembly
1) Turn the clutch hub face 1 toward the sleeve small groove
2 on the outer circumference.
2) Install the synchroniser assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing
the reverse gear side.
8. Mainshaft Nut
1) Mesh the 1st-2nd synchroniser with both the 1st and 3rd
gears (double engagement).
This will prevent the mainshaft from turning.
2) Install the mainshaft hub nut.
3) Use the mainshaft nut wrench to tighten the mainshaft nut
to the specified torque.
Wrench: 5-8840-2156-0 (J-37219)
Mainshaft Nut Torque N⋅m (kgf⋅m/lb⋅ft)
137 ± 20 (14 ± 2 / 101 ± 14.2)
4) Use a punch to caulk the mainshaft nut.
12.Counter Reverse Gear
1) Apply engine oil to the counter reverse gear and the reverse
gear.
2) Install the counter reverse gear to the counter gear.
Note the projection at either side of the counter reverse
gear.
The larger projection must be facing the intermediate plate.
19.Bearing Snap Ring
1) Select the snap ring, which will provide the minimum
clearance between the ball bearing and the snap ring.
There are six snap ring sizes available.
The snap rings are colour-coded to indicate their thickness.
Ball Bearing and Snap Ring Clearance mm (in)
Standard
0-0.15 (0-0.0059)
Snap Ring Availability mm (in)
Thickness mm (in) Color-Coding
1.1 (0.043) White
1.2 (0.047) Yellow
1.3 (0.051) Blue
1.4 (0.055) Pink
1.5 (0.059) Green
1.6 (0.063) Brow n
2) Use a pair of snap ring pliers to install the snap ring to the
counter 5th gear.
Snap Ring Pliers
The snap ring must be fully inserted into the reverse idle
r
shaft snap ring groove.
20.Reverse Gear Snap Ring
1) Select the snap ring, which will provide the minimum
clearance between the intermediate plate and the snap ring.
There are three snap ring sizes available.
The snap rings are colour-coded to indicate their thickness.
Intermediate Plate and Snap Ring Clearance mm (in)
Standard
0-0.15 (0-0.0059)
Snap Ring Availability mm (in
)
Thickness mm (in) Color-Coding
1.2 (0.047) White
1.3 (0.051) Yellow
1.4 (0.055) Blue
2) Use a pair of snap ring pliers to install the snap ring to the
reverse idler shaft.
Snap Ring Pliers
The snap ring must be fully inserted into the reverse idle
r
shaft snap ring groove.
21.Thrust Washer and Lock Ball
1) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance mm (in)
Standard
0.10-0.25 (0.0039-0.0098)
If required, replace the existing thrust washer with a new thrust
washer to bring the clearance to specification.
There are four thrust washer sizes available.
The snap rings are colour-coded to indicate their thickness.
Thrust Washer Availability mm (in)
Thickness Color-Coding
7.9 (0.311) White
8.0 (0.315) Yellow
8.1 (0.319) Green
8.2 (0.323) Blue
2) Apply grease to the thrust washer and the lock ball.
3) Install the thrust washer and the lock ball.
28.Ball Bearing
Use the installer to install the ball bearing to the mainshaft.
Installer: 5-8840-2159-0 (J-37223)
INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT,
SHIFT ARM ASSEMBLY, AND INTERLOCK PI N
REASSEMBLY STEPS
1. Intermediate plate and gear assembly
2. 1st-2nd shift arm
3. 3rd-4th shift arm
▲4. 3rd-4th shift rod
▲5. Interlock pin
6. 1st-2nd shift rod
7. Rev-5th shift arm and reverse inhibitor
8. Rev-5th shift rod
9. Spring
10. Detent ball
11. Detent spring
▲12. Detent spring plate and gasket
IMPORTANT OPERATIONS
4.3rd-4th Shift Rod
5.Interlock Pin
1) Install the interlock pin to the shift rod.
2) Install the shift rod together with the interlock pin to the
intermediate plate.
Do not allow the interlock pin to fall from the shift rod.
12.Detent Spring Plate and Gasket
1) Install the new-detent plate and new gasket onto the
transmission case into the correct direction.
2) Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
20 ± 4 (2.0 ± 0.4/14 ± 3)
MAJO R COMPONENTS
REASSEMBLY STEPS
▲1. Intermediate plate with gear assembly
▲2. Rear cover with oil seal
▲3. Transmission case
▲4. Front bearing snap ring
▲5. Counter front bearing snap ring
▲6. Front cover with oil seal
▲7. Gear control box assembly
8. Speedometer driven gear and
speedometer sensor
IMPORTANT OPERATIONS
1. Intermediate Plate with Gear Assembly
1)
A
pply a light coat of oil to the transmission case top gea
r
shaft ball bearing fitting faces and the shift rods.
This will facilitate smooth installation.
2) Install the intermediate plate assembly.
3) Pull out the top gear shaft until the ball bearing snap ring
groove protrudes from the transmission case front cove
r
fitting face.
Avoid subjecting the mainshaft to sudden shock or stress.
2. Rear Cover with Oil Seal
3. Transmission Case
1) Apply recommended liquid gasket or its equivalent to the
transmission case and rear cover fitting surfaces.
2) Install the rear cover and the transmission case to the
intermediate plate.
3) Tighten the rear cover blots to the specified torque
Rear Cover Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
39 ± 8 (4.0 ± 0.8 / 29 ± 6)
4. Front Bearing Snap Ring
5. Counter Front Bearing Snap Ring
Use a pair of snap ring pliers to install the snap rings to the
mainshaft.
The snap rings must be fully inserted into the ball bearing snap
ring groove.
6. Font Cover with Oil Seal
1) Apply recommended liquid gasket or its equivalent to the
through bolt threads.
2) Install the new gasket and the front cover to the
transmission case.
Take care not to damage the oil seal.
3) Tighten the front cover bolts to the specified torque.
Front Cover Bolt Torque N⋅m (kgf⋅m/lb⋅ft
)
18.6 ± 3.9 (1.9 ± 0.4/13.7 ± 2.9)
7. Speedometer Driven Gear and Speedometer Sensor
1) Install the O-ring to the speedometer driven gear bushing.
2) Install the driven gear to the speedometer driven gea
r
bushing.
3) Align the matching m ark s on plate 1 and bush 2, and then
tighten the bolt.
Bolt Torque N⋅m (kgf⋅m/lb⋅ft
)
14.7 (1.5 / 10.8)
4) Install the speedometer sensor.
Speedometer Sensor Torque N⋅m (k gf⋅m/lb⋅ft)
27 (2.8 / 20)