manual transmission ISUZU TF SERIES 2004 Service Manual

WORKSHOP MANUAL

TF SERIES




MANUAL TRANSMISSION
(MUA MODELS)





SECTION 7B1

MANUAL TRANSMISSION 7B1-1

SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (4





2)
Service Precaution .......................................................................................................... 7B1 – 3
General Description ........................................................................................................ 7B1 – 4
Rear Oil Seal (4




2) ........................................................................................................... 7B1 – 5
Transmission (4




2) ......................................................................................................... 7B1 – 7
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
Disassembled View ..................................................................................................... 7B1 –23
Disassembly ................................................................................................................ 7B1 –24
Inspection and Repair ................................................................................................. 7B1 –25
Reassembly ................................................................................................................. 7B1 –26
Reverse Gear and 5th Gear ............................................................................................ 7B1 –27
Disassembled View ..................................................................................................... 7B1 –27
Disassembly ................................................................................................................ 7B1 –29
Inspection and Repair ................................................................................................. 7B1 –31
Reassembly ................................................................................................................. 7B1 –31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –38
Disassembled View ..................................................................................................... 7B1 –38
Disassembly ................................................................................................................ 7B1 –40
Inspection and Repair ................................................................................................. 7B1 –42
Reassembly ................................................................................................................. 7B1 –45
Main Data and Specifications ......................................................................................... 7B1 –51

7B1-2 MANUAL TRANSMISSION

Troubleshooting ............................................................................................................... 7B1 –55
Special Tools (4





2) .......................................................................................................... 7B1 –62


MUA (4





4)
Service Precaution .......................................................................................................... 7B1 –63
General Description ........................................................................................................ 7B1 –64
Transmission (4




4) ......................................................................................................... 7B1 –65
Disassembled View ..................................................................................................... 7B1 –65
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
Disassembled View ..................................................................................................... 7B1 –82
Disassembly ................................................................................................................ 7B1 –83
Inspection and Repair ................................................................................................. 7B1 –83
Reassembly ................................................................................................................. 7B1 –84
Reverse Gear and 5th Gear ............................................................................................ 7B1 –85
Disassembled View ..................................................................................................... 7B1 –85
Disassembly ................................................................................................................ 7B1 –86
Inspection and Repair ................................................................................................. 7B1 –88
Reassembly ................................................................................................................. 7B1 –88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –94
Disassembled View ..................................................................................................... 7B1 –94
Disassembly ................................................................................................................ 7B1 –96
Inspection and Repair .............................................................................................. 7B1 – 98
Reassembly .............................................................................................................. 7B1 – 101
Main Data and Specifications ..................................................................................... 7B1 – 107
Troubleshooting ........................................................................................................... 7B1 – 111
Special Tools (4





4) ...................................................................................................... 7B1 – 118

MANUAL TRANSMISSION 7B1-3

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 SERVICE 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.

7B1-4 MANUAL TRANSMISSION

General Description
MUA Transmission (4




2)
A07R300006
The MUA is a constant mesh transmission,
synchronized in all speeds. The transmission has been
designed to provide low shift effort and low gear noise.
Principle parts of the transmission are the integral clutch
housing, the intermediate plate, the rear cover, and the
gears.
The transmission control box is built into the
transmission.

MANUAL TRANSMISSION 7B1-5

Rear Oil Seal (4





2)
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.

7B1-6 MANUAL TRANSMISSION

Torque : 63 N·m (6.4 kg·m/46 lb·ft)
4. Install center bearing on crossmember.
Torque : 69 N·m (7.0 kg·m/51 lb·ft)
5. Check transmission fluid level.
6. Lower vehicle.

MANUAL TRANSMISSION 7B1-7

Transmission (4





2)
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

7B1-8 MANUAL TRANSMISSION

Removal
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).
Refer to the section “Floor Console”.
745R300006

Legend
(1) Knob
(2) Rear Floor Console
(3) Front Floor Console

5. Remove grommet assembly (4).



RTW47BMH000101

MANUAL TRANSMISSION 7B1-9

6. Remove gear control lever (5).
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.

401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)
150R300003

10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the
transmission.

Neutral Switch


Back up Switch

Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly