@5 MZZ Transmission

2011MY
2011MY
WORKSHOP MANUALTRANSMISSION (MZZ model)
No.MGMZZ-WE-1101
WORKSHOP MANUAL
TRANSMISSION
(MZZ model)
MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
0
1
Section
GENERAL INFORMATION
ENGINE
SUSPENSION
DRIVELINE/AXLE
BRAKES
TRANSMISSION/TRANSAXLE
6
7
STEERING
HVAC
RESTRAINTS
BODY, CAB AND ACCESSORIES
10 CONTROL SYSTEMS
11 FRAME AND FRAME ACCESSORIES
0A
1A
1B
1C
1D
1E
1F
1G
1H
1I
1J
1K
1L
2A1
2B
2C
2D
3A1
3A2
3C1
3C2
3C3
3D
4A2
4A3
4B2
4B3
4C
4C1
4D
4E
4F
4G
5A
5B
5C
5E
5G
5G1
6B
7A
7B
7C
8A
8B
8C
9A
9B
9C
9D
9E
9F
9G
9H
9I
9K
9L
10B
11A
Sub Section
General Information
Engine Control System
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Emission Control
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Induction
Pre-Heating System
Power Take-Off (PTO)
Air Suspension Control System
Front Suspension
Rear Suspension
Wheel and Tire System
Front Differential
Rear Differential
Propeller Shaft
Front Axle
Rear Axle
Transfer Case
Brake Control System (Air Over)
Brake Control System (Full Air)
Brake (Air Over)
Brake (Full Air)
Anti-Lock Brake (ABS)
Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
Parking Brake
Hill Start Aid (HSA)
Speed Retarder System
Trailer Brake
Transmission Control System
Automatic Transmission
Manual Transmission
Clutch
Power Take-Off (PTO)
Side Power Take-Off
Power Steering
Heating and Ventilation
Manual Air Conditioning
Automatic Air Conditioning
Seat Belt
Supplemental Restraint System (SRS)
SRS Control System
Lighting System
Wiper/Washer System
Entertainment
Wiring System
Instrumentation/Driver Info.
Body Structure
Cab
Seats
Security and Lock
Exterior/Interior Trim
Cab Mounting
Vehicle Control
Frame
MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 2
MGMZZ-WE-1001.book 1
Manual Transmission (MZZ)
Manual Transmission
(MZZ)
TABLE OF CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 5C-2
Description of Function and Operation . . . . . . . 5C-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 5C-3
Primary Specifications. . . . . . . . . . . . . . . . . . . . 5C-4
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Shift Lever ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8
Gear Control Cable . . . . . . . . . . . . . . . . . . . . . . 5C-10
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10
Vehicle Speed Sensor and Speedometer
Driven Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13
Backup Light and Neutral Switch . . . . . . . . . . . . 5C-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
List of Tightening Torques . . . . . . . . . . . . . . . . 5C-18
Transmission ASM . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-20
MZZ Transmission . . . . . . . . . . . . . . . . . . . . . . . 5C-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-29
Top Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-41
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-41
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-42
Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-43
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-44
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-47
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-52
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-52
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-53
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-56
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-56
5C-1
5C-2
General Description
Description of Function and Operation
MFWB5CMF000101
MZZ transmission
Gear
The MZZ type transmission uses synchromesh
type for gears except 1st and Rev. Helical gears
are used for all gears to reduce noise. For the
synchromesh mechanism, a type that uses balls
and springs instead of keys is adopted. In addition
to using a special brass blocking ring to improve
the synchronizing performance, a 3-cone type is
used for the 1st, Reverse, 2nd and 3rd gears to
reduce the operating force.
Bearing
A roller bearing is used for the bearing of the main
shaft. A taper roller bearing is used for bearings at
both ends of the counter shaft. To ensure durability
and quietness, needle roller bearings are used for
the bearings for 1st gear, 2nd gear, 3rd gear, 4th
gear, 6th gear, and the reverse gear.
Transmission case
The structure of the clutch housing and the
transmission case is in the form of cylindrical
cases (3 pieces) made of lightweight aluminum
die-cast, and there is a side cover for installing the
power take-off unit on the left side. A gear control
box is installed on top of the transmission case.
5C-3
Functional Inspection
Condition
Abnormal noise
Difficulty in shifting
Falling out of gears
Oil leakage
Possible Cause
Correction
Wear on the flywheel pilot bearing
Replace
Wear or damage on the bearing (main

shaft and counter shaft)
Replace
Wear, scratches, or damage on the

gear (main shaft, counter shaft, and
reverse idle gear)
Replace
Wear on the spline (main shaft and

synchronizer clutch hub)
Replace
Scorching on the gear or bearing thrust
Replace
Not enough backlash in the mating gear
Replace
Failure in clutch pedal play
Adjust
Wear on the sliding section of the gear

shift lever
Perform
repair
or
lubrication of grease
Wear on the sliding section of the shift

block, shift rod, or control box
Replace
Wear on the groove of the synchronizer

sleeve or the shift arm
Replace the worn-out part
Wear on the thrust washer, collar, or

gear thrust surface (play in the main
shaft and counter shaft thrust)
Wear on the synchronizer components
Replace
Wear on the detent ball, ball seat, and

spring
Replace the detent ASM
Wear on the sliding section of the

control box or shift rod
Replace
Wear on the groove of the synchronizer

sleeve or the shift arm
Wear on the thrust washer, collar, or

gear thrust surface (play in the main
shaft and counter shaft thrust)
Wear or damage on the bearing
Replace
Wear on the spline (main shaft and

synchronizer hub)
Replace
Weakening or damage
synchronizer spring
Replace
to
the
replacement,
Loosening of the drain plug or the filler

plug
Tighten the plugs and replenish oil
Breaking of the gasket
Replace
Wear or damage on the oil seal
Replace
Transmission oil inspection

1. Remove the filler plug.
2. As shown in the diagram, inspect via the filler plug
hole whether the oil level comes up to the lower
surface of the hole.
3. Replenish the oil if the oil level is below the
specified level.
Transmission oil
GL-5 BESCO GEAR OIL SH 80W-90 or
equivalent
4. Tighten the filler plug to the specified torque.

Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
5C-4

2. Stop the engine, remove the drain plug, and then
drain the oil.
CAUTION:
When the temperature of the engine is high, be careful
so as not to burn yourself.
3. Tighten the drain plug.
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
4. Remove the filler plug.

5. From the filler plug hole, fill oil up to the lower edge
of the filler plug hole.
Oil capacity [Reference value]
Without side PTO
4.4L
(1.16 US gal./0.97 Imp gal.)
With side PTO
5.3L
(1.40 US gal./1.17 Imp gal.)
LNW25CSH054301
Legend
1. Filler plug
2. Drain plug
6. Tighten the filler plug to the specified torque.

Replacement of the transmission oil
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
1. Start the engine and warm up the transmission

body sufficiently.
Primary Specifications
Gear ratio
Model
MZZ6W
Number of primary teeth
46 / 25
1st
45 / 13
6.369
2nd
43 / 21
3.767
3rd
35 / 27
2.385
4th
29 / 37
1.442
5th
Direct coupling
1.000
6th
18 / 46
0.720
Rev
45 / 26 / 13
6.369
Oil capacity
[reference value]
Transmission oil
Without side PTO
4.4L(1.16 US gal./0.97 Imp gal.)
With side PTO
5.3L(1.40 US gal./1.17 Imp gal.)

API GL-5 BESCO GEAR OIL SH 80W-90 or equivalent
5C-5
Special Tool
Illustration
Tool Number/ Description
Illustration
5-8840-2751-0
Oil seal installer
5884027510
5-8840-2558-0
Oil seal installer
5884025580
9-8529-2101-0
Flange holder
9852921010
5-8840-2753-0
Bearing installer
5884027530
5-8840-2755-0
Bushing remover &
installer
5-8840-0007-0
Grip
5884027550
5-8840-2757-0
Bearing remover
5-8840-0027-0
Remover
5884027570
5-8840-2793-0
Oil seal protector
5-8840-0084-0
Sliding hammer
5884027930
5-8840-2802-0
Push puller
5-8840-2244-0
Bearing installer
5884022440
5884028020
5C-6

Illustration
5-8840-2023-0
Bearing installer
5884020230
5-8840-2345-0
Installer
5884023450
5-8840-2587-0
Bearing remover
5-8840-2245-0
Control box oil seal
installer
5884022450
5C-7
Shift Lever ASM

Components
1
8
7
4
3
2
10
17
11
12
13
14
15
18
16
MFW75CMF000201
Legend
1. Shift Lever Knob
2. Gear Control Cover
3. Shift Lever ASM
4. Ball
5. Select Lever
6. E-ring
7. Spring Pin (RHD only)
8. Ring (RHD only)
9. Shift Lever
Disassembly
1. Remove the shift lever knob.
2. Remove the bolt and clip, and then remove the
boot and cover.
3. Separate the inner cable from the shift lever and
select lever, remove the clip holding the outer
cable, and then remove the shift cable and select
cable.
4. Remove the bolt and nut that are holding the
bracket ASM in place, and then remove the shift
lever ASM.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Cover Plate
Ball Seat
Rubber Seat (except RHD with power assist)
Spring
Distance Piece
Cushion Rubber
Bracket ASM
Select Cable
Shift Cable
5C-8
5. Remove the E-ring (1), select lever (2), and spring

(3), and remove the ball (4) from the select lever
(2).
7. Pull out the spring pin (RHD only) (1) from the shift
lever (3), and remove the ring (RHD only) (2).
2
1
2
1
MFW75CSH001601
MFW75CSH001701
6. Remove nut (5), and then remove the shift lever

(1), the cover plate (2), the ball seat (3), and the
rubber seat (except RHD with power assist) (4)
from the bracket ASM.
1
2
8. Inspect the following parts.

Clean each part.
If wear, damage, or other abnormalities are
found in the disassembled parts, repair or
replace the defective parts.
Inspect the ball seat and rubber seat for wear or
damage.
Reassembly
Apply grease (Multemp SA or equivalent) to the
sliding section.
1. Assemble the ring (RHD only) (2) to the shift lever
(3), and then tap the spring pin (RHD only) (1).
2
1
5
MFW75CSH001501
MFW75CSH001601

2. Assemble the cover plate (2), the ball seat (3), and
the rubber seat (4) (except RHD with power assist)
to the shift lever (1), align the stud of the cover
plate with the bracket ASM, and then tighten the
stud with the nuts (5).
Tightening torque:
5C-9
Install the bushing (1) so that it faces the select

lever side.
6 Nm (0.6 kgm / 52 lbin)
1
2
4
1
MFW75CSH005501
MFW75CSH001501
3. Assemble the ball (4) to the select lever (2).

4. Assemble the spring (3) and the select lever (2) to
the shift lever ASM, and then fix them with the Ering (1).
2
1
MFW75CSH001701
5. Install the shift lever ASM to the cab.

Tighten the fixing bolts and nuts.
Tightening torque:
24 Nm (2.4 kgm / 17 lbft)
6. Connect the shift cable to the shift lever.

Tightening torque:
24 Nm (2.4 kgm / 17 lbft)
7. Connect the select cable to the select lever.
8. Assemble the shift and the outer cable of the

select cable to the bracket ASM and install with the
clip.
NOTE:
Check to see that there are no cracks or misalignments
caused by excessive tapping of the clip.
9. Install the boot and cover.
10. Install the shift lever knob.
5C-10
Gear Control Cable

Components
Installation length of the select cable: 210 mm

(8.27 in)
Cab side
MFW75CSH001301
MFW75CSH001201
Legend
1. Select cable
2. Shift cable
2. Install the select cable (cab side).

Install the bushing (1) so that it faces the select
lever side.
Transmission side
NOTE:
Do not hold the guide pipe section of the control
cable, when you install or remove the control cable,
as doing so could break the guide pipe.
Check to see that there are no cracks or
misalignments caused by excessive tapping of the
clip.
MFW75CSH005601
Legend
1. Select cable
2. Shift cable
Installation
1. Adjust the length of the select cable (cab side) to
the specified value.
MFW75CSH005501
3. Adjust the length of the shift cable (cab side) to the

specified value.
Installation length of the shift cable: 210 mm
(8.27 in)

NOTE:
Do not hold the guide pipe section of the control
cable, when you install or remove the control cable,
as doing so could break the guide pipe.
Check to see that there are no cracks or
misalignments caused by excessive tapping of the
clip.
5C-11
2
3
MFW75CSH001101
Legend
1. Lock nut
2. Tightening nut
3. To center of joint
4. Cab floor
MFW75CSH001401
4. Install the shift cable (cab side).

Loosen the lock nut on the ball joint, turn the
ball joint and after adjusting the cable length,
tighten each nut at the specified torque.
Tightening torque
Ball joint lock nut:
13 Nm (1.3 kgm / 113 lbin)
Ball joint tightening nut (M8):
24 Nm (2.4 kgm / 17 lbft)
5. Adjust the length of the select cable (transmission

side) to the specified value.
NOTE:
Measure the length between the end of bracket and
the center of ball joint (1).
If the control cable boot is twisted, loosen the lock
nut (2) to correct the twist.
Installation length of the select cable: 275mm
(10.83 in)
MFW95CSH000401
6. Install the select cable (transmission side).
5C-12
Loosen the lock nut on the ball joint, turn the

ball joint and after adjusting the cable length,
tighten each nut at the specified torque.
Tightening torque
Ball joint lock nut :
13 Nm (1.3 kgm / 113 lbin)
Ball joint tightening nut (M8) :
24 Nm (2.4 kgm / 17 lbft)
7. Adjust the length of the shift cable (transmission
side) to the specified value.
NOTE:
Measure the length between the end of bracket and
the center of ball joint (1).
If the control cable boot is twisted, loosen the lock
nut (2) to correct the twist.
Installed length of the shift cable
Length
With power assist
210 mm (8.27 in)
Without power assist
220 mm (8.66 in)
2
MFW95CSH000601
8. Install the shift cable (transmission side).

Rotate the ball joint without moving the shift
lever and after adjusting it to its specified
length, tighten it at its specified torque.
Tightening torque
Ball joint lock nut:
13 Nm (1.3 kgm / 113 lbin)
Ball joint tightening nut (M8):
24 Nm (2.4 kgm / 17 lbft)
5C-13
Vehicle Speed Sensor and Speedometer Driven Gear

Removal
1. Disconnect the vehicle speed sensor connector.
2. Remove the vehicle speed sensor from the
bushing.
3. Remove the fixing bolt and then remove the
retainer plate.
4. Remove the bushing with the speedometer driven
gear.
5. Remove the speedometer driven gear from the
bushing.
Assemble the retainer plate to the bushing and

insert it to the transmission in alignment with
the position of the bushing, so that the number
stamped on the flange surface of the bushing
seen in the window on the retainer plate
corresponds to the number of teeth of the
assembled speedometer driven gear. Then, fix
it to the rear cover with the retainer plate and
screw.
The following diagram shows the case where
the number of speedometer driven gear teeth is
12.
Tightening torque:
20 Nm (2.0 kgm / 14 lbft)
2
1
3
4
1
5
6
3
2
LNW25CSH051201
Legend
1. Coupling pin
2. Vehicle speed sensor
3. Retainer plate
4. Bushing
5. O-ring
6. Speedometer driven gear
Installation
1. Apply engine oil to the speedometer driven gear
and assemble it to the bushing.
2. Install the bushing to the rear cover and secure it
with the retainer plate.
LNW6Z0SH000101
Legend
1. Speedometer driven gear
2. Bushing
3. Retainer plate
3. Assemble the vehicle speed sensor to the bushing.
Make sure align the slit of speedometer driven
gear shaft (2) and the protruding portion of
coupling pin (1) and insert the speedometer
driven gear.
5C-14
LNW85CSH000101
Tightening torque:
25 Nm (2.5 kgm / 18 lbft)
4. Connect the vehicle speed sensor connector.
5C-15
Backup Light and Neutral Switch

Removal
1. Disconnect the harness connector.
2. Remove the reverse switch (2) (black connector).
3. Remove the neutral switch (1) (black connector).
Remove any old sealing agent, apply liquid

gasket to the application area (a) of the switch
threaded portion, and install the switch.
Liquid gasket:
ThreeBond TB1141 or equivalent
Tightening torque:
34 Nm (3.5 kgm / 25 lbft)
2. Install the reverse switch.

Remove any old sealing agent, apply liquid
gasket to the application area (a) of the switch
threaded portion, and install the switch.
Liquid gasket:
ThreeBond TB1141 or equivalent
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
NOTE:
The application area for liquid gasket (a) must be less
than half the length of the threaded portion.
MFWB5CSH000401
Inspection
The switch is normal if there is continuity between
both ends of the switch when in this state, and no
continuity between both ends of the switch when
the ball is pressed.
Operation stroke of the switch
= 0.93 mm (0.04 in)
LNW55CSH000101
3. Connect the harness connector.
0.93mm
(0.04in)
LNW47BSH000201
Installation
1. Install the neutral switch.
5C-16
Rear Oil Seal

Components
1
4
LNW25CMF003401
Legend
1. Oil seal
2. Parking Brake cable
3. Parking Brake ASM
Removal
1. Remove the rear propeller shaft ASM.
Refer to "Rear Propeller Shaft ASM" in Section
3C1 Propeller Shaft.
2. Remove the parking brake cable.
Refer to "Parking Brake Lever" in Section 4D
Parking Brake.
3. Remove the parking brake drum, coupling driver,
and O-ring.
Fully raise the crimped section (2 locations) of
the lock nut and remove the lock nut using the
flange holder: 9-8529-2101-0.
4. Remove the parking brake ASM.
Refer to "Parking Brake" in Section 4D Parking
Brake.
5. Remove the rear oil seal using a flat-blade screw
driver.
4. Parking Brake Drum and Cup Ring Driver

5. Rear Propeller Shaft ASM
Installation
1. Apply engine oil to the external circumference of a
new oil seal, and firmly fit the oil seal into the rear
cover using the oil seal installer: 5-8840-2751-0.
Apply BESCO L-2 grease or equivalent to the
lip section of the oil seal.
NOTE:
Be careful not to damage the lip section of the oil seal.
5C-17
5-8840-2751-0
MIN
5.0mm (0.20 in)
B
MIN
5.0mm (0.20 in)
LNW25CSH038301
2. Install the parking brake ASM.

Brake.
3. Install the parking brake drum and coupling driver.
a. Apply engine oil to the O-ring, and then install
the coupling driver and O-ring.
b. Use a new lock nut, apply engine oil to the seat
surface, and then tighten the lock nut using the
flange holder: 9-8529-2101-0.
Tightening torque:
382 Nm (39.0 kgm / 282 lbft)
After tightening the lock nut to the specified

torque, align the lip section of the nut with
the V groove at the end of the shaft. Firmly
caulk the nut in 2 locations using a chisel
with a tip of a radius of approximately 1 mm
(0.04 in) x 60 so that the length is 5 mm
(0.2 in) or longer (B), and the gap between
the bottom of the V-groove of the shaft and
the nut and lip is 2.5 mm (0.1 in) or shorter
(A).
NOTE:
If any crack is found on the lip section of the nut after
caulking, replace the lock nut and caulk it again.
MAX
2.5mm (0.10 in)
A
MAX
2.5mm (0.10 in)
LNWA5CMH000101
4. Install the parking brake cable.

Refer to "Parking Brake Lever" in Section 4D
Parking Brake.
5. Install the rear propeller shaft ASM.
Refer to "Rear Propeller Shaft ASM" in Section
3C1 Propeller Shaft.
5C-18
List of Tightening Torques
MFW75CSF000301
Legend
(a)
382 Nm (39.0 kgm / 282 lbft)
5C-19
Transmission ASM
Removal
The transmission case and clutch housing are made of
aluminum. Take sufficient care to prevent them from
becoming damaged. In particular, damage to the rib
causes strength reduction. It is necessary to exercise
extreme precaution.
In addition, be careful not to injure yourself when
handling heavy components such as cases.
Place chock block to the wheels.
Tilt the cab.
Remove the battery cable (-).
Place an alignment mark, and remove the PTO

propeller shaft ASM.
Disconnect the PTO air hose.
6. Disconnect the frame harness connector from the
transmission harness connector.
7. Remove the exhaust pipe bracket.
NOTE:
Protect disconnected terminals by putting a plastic bag
over them so as to prevent dust and foreign materials
from mixing in.
Lift up the vehicle using a lifter.
1. Remove the filler plug and O-ring from the
transmission.
2. Remove the drain plug and O-ring from the
transmission.
Drain the transmission oil. When draining the
oil, check the amount of oil, and check whether
there are any foreign materials such as metal
chips.
3. Remove the propeller shaft ASM.
Place an alignment mark, and remove the
propeller shaft ASM.
Remove the propeller shaft guard, and tie the
propeller shaft to the chassis side using a
lashing belt, etc.
4. Disconnect the inner cable of the parking brake
from the lever and separate the outer cable from
the bracket. (with parking brake)
MFWB5CSH000601
5. Remove the PTO propeller shaft ASM and air

hose. (with side PTO)
MFWB5CSH000501
8. Remove the starter motor ASM.

9. Remove the power assist air hose.
Disconnect the power assist air hose.
10. Remove the clutch booster ASM.
Remove the return spring.
Remove the spring hanger in the clutch lever
area, and disconnect the push rod from the
clutch lever.
Remove the clutch booster ASM from the
transmission and fix it to the frame.
Refer to Clutch Booster in Section 5E Clutch
(MZZ).
11. Disconnect the select cable and the shift cable.
Separate the select cable from the select relay
lever.
Separate the shift cable from the power assist.
Remove the bracket of the select and shift
cables from the transmission.
5C-20
MFW75CSH005601
12. Remove the rear engine mounting from the cross

member.
13. Remove engine - transmission installation bolts.
Remove brackets and cables characteristic to
vehicle models.
Support transmission with a transmission jack.
Remove engine - transmission bolts (10 pcs.).
14. Remove the transmission ASM.
Remove the transmission ASM from the engine
using a transmission jack.
MFWB5CSH000501
3. Install the rear engine mounting to the cross

member.
4. Connect the select cable to the select relay lever.
Refer to Gear Control Cable in this section.
Tightening torque:
24 Nm (2.4 kgm / 17 lbft)
5. Install the shift cable to the power assist.

Refer to Gear Control Cable in this section.
Tightening torque:
24 Nm (2.4 kgm / 17 lbft)
Installation
1. Mount the transmission ASM.
Apply grease (variant S or equivalent) to the top
gear shaft spline.
Slowly operate the transmission jack to lift the
transmission to make it closer to the engine.
2. Tighten the engine - transmission installation bolt
at its specified torque.
Tightening torque:
44 Nm (4.5 kgm / 33 lbft)
The exhaust pipe bracket shall also be

tightened.
Tightening torque:
44 Nm (4.5 kgm / 33 lbft)

MFW75CSH005601
6. Install the clutch booster ASM.

Install the clutch booster ASM bracket to the
transmission case.
Tightening torque:
53 Nm (5.4 kgm / 39 lbft)
Connect the push rod to the clutch lever.

Install the return spring.
Refer to Clutch Booster in Section 5E Clutch
(MZZ).
7. Install the power assist air hose.

Install the air hose to be connected to the
power assist using 2 wrenches.
Tightening torque:
34 Nm (3.5 kgm / 25 lbft)
8. Install the starter motor ASM.

Connect the starter motor harness and ground.
9. Connect the frame harness connector to the
transmission harness connector.
10. Connect PTO propeller shaft ASM and air hose.
(with side PTO)
11. Mount the cable bracket and the joint section of the
parking brake. (with parking brake)
MFWB5CSH000601
12. Mount the propeller shaft ASM.

Mount the propeller shaft guard.
13. Install transmission drain plug and O-ring.
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
14. Fill gear oil (BESCO GEAR OIL (SH 80W-90) or

equivalent) from the filler hole, and then install the
filler plug.
Tightening torque:
39 Nm(4.0 kgm / 29 lbft)
15. Connect the battery cable (-).
5C-21
5C-22
MZZ Transmission
Components
2
3
5
32
4
31
30
27
29
10
11
28
13
12
26
25
34
22 21
24
35
14
20
23
33
19
18
37
36
38
17
16
15
39
MFWB5CLF000101
Legend
1. Clutch Housing
2. Bushing; Clutch Housing
3. 4th-5th Shift Arm, 4th-5th and 6th Shift Rod, 6th
Shift Block
4. Interlock Plate
5. Control Box
6. Reverse Switch
7. Detent ASM
8. Filler Plug
9. Detent ASM
10. Spring Pin
11. 6th relay Lever
12. Snap Ring
13. 6th Shift Arm and Subshift Rod
14. Speedometer Drive Gear
15. Snap Ring
16. 6th Clutch Hub ASM and Sleeve
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
6th Gear and Needle Bearing

Reverse Idle Shaft
Reverse Idle Gear and Needle Bearing
Retainer
Shim; Counter
Counter Rear Bearing Outer Race
Detent ASM
Reverse Idle Cover
PTO Cover
Sensor Dummy Plug
Transmission Case
Detent ASM
1st-Reverse and 2nd-3rd Shift arm, Shift Rod,
1st-Reverse Shift Block
30. Front oil seal
31. Bearing Outer Race
32. Magnet

33.
34.
35.
36.
5C-23
37. Needle Bearing; Main End

38. Rear Oil Seal
39. Parking Brake ASM
Speedometer Driven Gear

Rear Cover
Parking Brake Cable Bracket
Drain Plug
40
41
42
MFWB5ELF000601
Legend
40. Top Gear Shaft ASM
41. Main Shaft ASM
Disassembly
CAUTION:
The transmission case and clutch housing are made of
aluminum. Take sufficient care to prevent them from
becoming damaged. In particular, damage to the rib
causes strength reduction. It is necessary to exercise
extreme precaution.
In addition, be careful not to injure yourself when
handling heavy objects such as cases and gears.
1. Disconnect each harness connector.
42. Counter Shaft ASM
Neutral switch
Reverse switch
2. Remove the shift block, release bearing, clutch
shaft and shift fork .
Refer to "Clutch ASM" in Section 5E Clutch.
3. Remove the adjust hole cover fixing bolt, and then
remove the parking brake drum.
4. Fully raise the crimped section (2 locations) of the
lock nut for the coupling driver and remove the lock
nut using the flange holder: 9-8529-2101-0.
5C-24
5. Remove the coupling driver and O-ring.

6. Remove the parking brake ASM.
Brake.
7. Remove the parking brake cable bracket from the
transmission case.
8. Remove the filler plug and O-ring.
9. Remove the drain plug and O-ring.
Drain the transmission oil. When draining the
oil, check the oil amount, and check whether
there are any foreign materials such as metal
chips.
10. Remove the speedometer drive gear.
11. Remove the reverse switch.
12. Remove the detent ASM.
16. Remove the reverse idle cover (2).
2
1
LNW25CSH049801
17. Remove the rear cover ASM.

18. Check the oil seal on the rear cover for wear or
damage. If wear or damage is found, remove it
from the rear cover using a flat-blade screwdriver.
19. Remove the needle bearing; main end from the
rear cover using the remover: 5-8840-0027-0 and
the sliding hammer: 5-8840-0084-0.
5-8840-0084-0
5-8840-0027-0
1
MFW75BSH003601
Legend
1. Detent ASM
2. 4th-5th shift arm
3. 6th shift block
4. 1st reverse shift block
5. 2nd-3rd shift arm
6. 1st-reverse shift arm
13. Remove the control box.
14. Remove the interlock plate.
15. Remove the PTO cover (1).
LNW25CSH048501
20. Remove the speedometer drive gear.

21. Remove the 6th relay lever (1).
22. Remove the 6th shift arm (3) and 6th sub shift rod
(4).
Punch out the spring pin (2) using a spring pin
remover.
5C-25
25. Disassemble the 6th clutch hub ASM and sleeve.
2
3
MFW45DSH005501
2
3
4
LNW25CMH002301
23. Remove the snap ring; 6th clutch hub using snap
ring pliers.
24. Remove the 6th clutch hub ASM, sleeve, 6th
blocking ring, 6th gear, and needle bearing from
the counter shaft using a puller.
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
26. Remove the retainer from the transmission case.
27. Pull out the reverse idle shaft, and then remove the
reverse idle gear and needle bearing.
LNW25CSH048601
LNW25CSH037301
28. Remove the snap ring; rear outer from the main
shaft rear bearing.
29. Remove the shim; counter.
5C-26
30. Remove the spring pin; 4th-5th shift rod and 6th
shift rod.
LNW25CSH037501
LNW55CSH000201
31. Remove the transmission case from the clutch

housing.
32. Remove the counter rear bearing outer race from
the transmission case.
34. Remove the 1st-reverse and 2nd-3rd shift rod, 1streverse shift arm, 3rd-2nd shift arm, and 1streverse shift block.
When punching out the spring pin, place the
round bar at the opposite side of the shift rod
and then remove the spring pin using the spring
pin remover while being careful not to damage
other parts.
LNW25CSH049401
33. Remove the 4th-5th shift rod, 6th shift rod, 6th shift
block, and 4th-5th shift arm.
When punching out the spring pin, place the
round bar at the opposite side of the shift rod
and then remove the spring pin using the spring
pin remover while being careful not to damage
other parts.
LNW25CSH051601
35. Remove the bushing from the 4th-5th shift arm

using the bushing remover and installer: 5-88402755-0.
36. Remove the bushing from the 3rd-2nd shift arm
using the bushing remover and installer: 5-88402755-0.
Use the bushing remover and installer with a
round bar that can be fully inserted.
5C-27
b. Install the bearing remover to the main shaft,

and fix it in place with the mounting lock nut.
Then use wires to hang the main shaft with a
hoist, and remove the top gear shaft ASM, main
shaft ASM, and counter shaft ASM from the
clutch housing at the same time, while widening
the snap ring for fixing the top gear shaft
bearing. Be careful not to drop the top gear
shaft ASM while it is being hoisted.
5-8840-2755-0
LNW25CSH027301
37. Remove the magnet from the clutch housing.

38. Remove the main shaft ASM, top gear shaft ASM
and counter shaft ASM.
a. Use a belt with a tightening function, such as a
lashing belt, securely tighten the main shaft
ASM, counter shaft ASM, and top gear ASM by
winding them in more than 2 locations to
prevent them from coming separating.
MFW45DSH003801
LNW25CSH054001
LNW25CSH050401
5C-28

- Measure the thickness of the tip of the shift
arm using a micrometer.
39. Inspect the clutch housing bushing for wear or

damage, and if wear or damage is found, remove it
from the clutch housing using pliers.
Thickness of the shift arm (mm (in))

Standard values
Limit for use
1st-reverse
10.75 - 10.85
(0.4232 - 0.4272)
10.2
(0.4016)
3rd-2nd
5th-4th
9.60 - 9.85
(0.3780 - 0.3878)
9.0
(0.3543)
6th
9.60 - 9.85
(0.3780 - 0.3878)
9.3
(0.3661)
MFW45DSH004001
40. Inspect the counter shaft front bearing for wear or

damage, and if wear or damage is found, remove
the bearing outer race from the clutch housing
using the bearing remover: 5-8840-2757-0 and
push puller: 5-8840-2802-0.
5-8840-2802-0
LNW25CSH013101
5-8840-2757-0
43. Inspect the speedometer driven gear and driven

gear bushing for wear.
Replace parts that are severely worn.
MFW45CSH000301
41. Inspect the front oil seal for wear or damage. If

wear or damage is found, remove it from the clutch
housing using a flat-blade screwdriver.
Inspect each part and if there is any wear, damage, or
other abnormalities, repair or replace the defective
parts.
42. Inspect each part of the shift mechanism. Repair
minor wear, bending and stepped wear. Replace
parts that are severely damaged, and parts that
exceed the usage limit.
Bending, wear, or damage to the shift rod and
shift arm
Thickness of the shift arm
LNW25CSH050501

Reassembly
1. Inspect the front oil seal for wear and damage. If
wear or damage is found, replace it with a new
one, apply engine oil on the outer circumference of
the oil seal, and then firmly fit the oil seal into the
clutch housing using the oil seal installer: 5-88402558-0.
5C-29
3. Inspect the clutch housing bushing for wear and

damage. If wear or damage is found, replace it
with a new one. When replacing it, firmly fit the
clutch housing using the bushing remover and
installer: 5-8840-2755-0.
5-8840-2755-0
NOTE:
5-8840-2558-0
MFW45DSH004301
LNW25CSH037801
2. Inspect the counter shaft front bearing for wear

and damage. If wear or damage is found, replace it
with a new one. When replacing it, firmly fit the
bearing outer race using the grip: 5-8840-0007-0
and bearing installer: 5-8840-2023-0.
The crimped section of the bushing must not

cover the groove section of the clutch housing
hole.
When installing, crimp 3 positions firmly while
avoiding the old crimped sections and the
groove sections.
When firmly fitting the bushing for a second
time or more, do so by orienting the notch
section towards the clutch housing side.
5-8840-0007-0
5-8840-2023-0
LNW25CSH051901
4. Install the main shaft ASM, top gear shaft ASM and
counter shaft ASM.
MFW45CSH000201
5C-30
a. Use a belt with a tightening function, such as a

lashing belt, securely tighten the main shaft
ASM, counter shaft ASM, and top gear ASM by
winding them in more than 2 locations to
prevent them from coming separating. Be
careful not to drop the top gear shaft ASM while
it is being hoisted.
d. Place the top gear shaft bearing outer snap ring

on the clutch housing beforehand, and align the
top gear shaft, counter shaft, and shift rod with
the clutch housing while spreading them out
using snap ring pliers.
NOTE:
Confirm that the snap ring is firmly installed.
Conduct operations carefully by keeping the shaft
hoisted vertically so as not to damage the front oil
seal.
MFW45DSH003801
b. Install the top gear shaft ASM, main shaft ASM,

and counter shaft ASM to the support stand so
that the top gear shaft ASM is on top.
c. Install the oil seal protector: 5-8840-2793-0 to
the main shaft.
5-8840-2793-0
LNW45CMH000701
LNW25CSH050601
5. Install the magnet to the clutch housing.

6. Inspect the 2nd-3rd shift arm bushing for wear and
with a new one. When replacing it, press and firmly
fit the 2nd-3rd shift arm bushing using the bushing
remover and installer: 5-8840-2755-0.
5C-31
7. Inspect the 4th-5th shift arm bushing for wear or

damage. Replace worn or damaged parts with new
ones. When making replacements, firmly fit the
4th-5th shift arm bushing using the bushing
remover and installer: 5-8840-2755-0.
5-8840-2755-0
MFW45DSH004501
Firmly fit the shift arm bushing while being

cautious of the direction and angle of the shift
arm bushing and then firmly tighten 3 positions
away from the old crimped sections and
matching surface of the bushing.
After firmly fitting in the shift arm bushing, make
sure that the shift rod slides smoothly.
15
MFW45DLH000301
8. Mount the 1st - reverse and 2nd-3rd shift rod (1) to

the 1st - reverse shift block (5), 2nd-3rd shift arm
(4), and 1st-reverse shift arm (2).
Align the spring pin holes and firmly fit the
spring pins (3) and (6) using a hammer.
When firmly fitting in the spring pin, place the
round bar on the opposite side of the shift rod,
and then firmly fit in the spring pin while being
careful not to damage other parts.
5C-32
2
4
3
4
5
LNW25CMH004201
9. Mount the 4th-5th and 6th shift rod (1) to the 4th5th shift arm (3) and 6th shift block (2).
Align the spring pin holes and firmly fit the
spring pin (4) using a hammer.
When firmly fitting in the spring pin, place the
round bar on the opposite side of the shift rod,
and then firmly fit in the spring pin while being
careful not to damage other parts.
MFW45CMH000201
10. Apply ThreeBond 1215 or equivalent to the mating

surface of the transmission case and clutch
housing, and then install them to the clutch
housing.
Before applying liquid gasket, remove water
and oil from the alignment surface. Then, apply
liquid gasket on the entire circumference
thoroughly so that the bead diameter is 2 mm
(0.08 in) or more.
Tightening torque:
46 Nm (4.7 kgm / 34 lbft)
MFW45DSH004601

11. Install the counter rear bearing outer race to the
transmission case.
12. Install the spring pin; 4th-5th shift rod and 6th shift
rod.
NOTE:
Replace spring pins that are deformed or damaged
with new ones, and make sure that it is securely
installed.
MFW55CSH000101
13. Install the counter shim.

a. Set the shift position to neutral.
b. Install the transmission ASM so that the
housing is on the bottom.
5C-33
Measure the depth from the rear end

surface of the transmission case to the end
surface of the outer ring of the counter shaft
rear bearing in 3 locations at an interval of
120, then calculate the average value.
Select a shim with a thickness that matches
the measured values in the following table.
Measured value (mm (in))
Greater than - Less than
Thickness of the shim

used
(mm (in))
2.13 - 2.19 (0.0839 - 0.0862)
1.98 (0.0780)
2.07 - 2.13 (0.0815 - 0.0839)
1.92 (0.0756)
2.01 - 2.07 (0.0791 - 0.0815)
1.86 (0.0732)
1.95 - 2.01 (0.0768 - 0.0791)
1.80 (0.0709)
1.89 - 1.95 (0.0744 - 0.0768)
1.74 (0.0685)
1.83 - 1.89 (0.0720 - 0.0744)
1.68 (0.0661)
1.77 - 1.83 (0.0697 - 0.0720)
1.62 (0.0638)
1.71 - 1.77 (0.0673 - 0.0697)
1.56 (0.0614)
1.65 - 1.71 (0.0650 - 0.0673)
1.50 (0.0591)
1.59 - 1.65 (0.0626 - 0.0650)
1.44 (0.0567)
1.53 - 1.59 (0.0602 - 0.0626)
1.38 (0.0543)
1.47 - 1.53 (0.0579 - 0.0602)
1.32 (0.0520)
1.41 - 1.47 (0.0555 - 0.0579)
1.26 (0.0496)
1.35 - 1.41 (0.0531 - 0.0555)
1.20 (0.0472)
14. Install the snap ring: rear outer to the main shaft
rear bearing.
NOTE:
Make sure to replace the snap ring with a new one if it
is deformed or damaged, and confirm that it is securely
installed.
15. Apply engine oil to the needle bearing, install the
reverse idle gear and needle bearing, then insert
the reverse idle shaft.
Set the identification groove (1) of reverse idle
gear toward the front side of the transmission.
LNW25CSH051801
c. Rotate the counter shaft at least 30 times to

warm up the taper roller bearing.
d. Select the counter shim.
5C-34

b. There are 3 ball grooves in the sleeve. Align the
positions so that the balls fall into the center of
the ball grooves.
LNW85CSH000201
MFW45DSH006401
c. Insert the sleeve (1) into the clutch hub (5) until
it lightly touches the block.
d. While pushing in the ball (2), block (3), and
spring (4), firmly insert the sleeve until the ball
falls into the ball groove on the sleeve.
The arrow mark indicates the front side of
the transmission.
1
2
3
5
LNW25CSH048601
16. Install the retainer to the transmission case.

Tightening torque:
26 Nm (2.7 kgm / 20 lbft)
NOTE:
Completely remove the seal agent on the threaded
portion of the transmission case, and replace all bolts
with new ones.
17. Assemble the 6th clutch hub ASM and sleeve
using the following procedure.
a. Install the block and spring to the clutch hub.
LNW25CSH050701

18. Apply engine oil to the inner diameter of the needle
bearing and blocking ring, assemble the 6th gear,
needle bearing, and 6th blocking ring, align the
position of the blocking ring groove on the clutch
hub, assemble the 6th clutch hub ASM and sleeve,
and then firmly fit them by using the bearing
installer: 5-8840-2244-0 and a hammer.
5C-35
5-8840-2244-0
2
3
4
LNW25CSH037701
19. Install the snap ring; 6th clutch hub using snap ring
pliers.
Select the thickest spring from among the 3
installable springs.
Thickness (mm (in))
Identification color
1.6 (0.063)
Pink
1.7 (0.067)
Light blue
1.8 (0.071)
Orange
1.9 (0.075)
Purple
NOTE:
When installing the snap ring, replace the snap ring
with a new one if it is deformed or damaged, and
confirm that it is securely installed.
20. Apply engine oil to the shift rod hole on the
transmission case, install the 6th shift arm (3) and
6th sub-shift rod (4), align the spring pin holes,
then firmly fit the spring pin (2).
21. Install the 6th relay lever (1).
Tightening torque:
44 Nm (4.5 kgm / 33 lbft)
LNW25CMH002301
22. Install the speedometer drive gear.

23. Install the needle bearing; main end.
Apply BESCO L2 grease or equivalent to the
inside of the needle bearing, and apply engine
oil to the internal diameter of the contact area
for the bearing on the rear cover.
Orient the stamped surface of the bearing
towards the outside, then firmly fit the needle
bearing into the rear cover from the outside
using the bearing installer: 5-8840-2753-0 and
grip: 5-8840-0007-0.
5-8840-0007-0
5-8840-2753-0
LNW25CSH049901
5C-36
24. Inspect the oil seal on the rear cover for wear and
with a new one when replacing the needle bearing;
main end, apply engine oil on the outer
circumference of the oil seal, and firmly fit the oil
seal into the rear cover using the oil seal installer:
5-8840-2751-0.
NOTE:
5-8840-2751-0
MFW45DMH001001
LNW25CSH038301

surface of the rear cover for the transmission case,
and install the rear cover.
and oil from the mating surface. Then, apply
liquid gasket thoroughly on the entire
circumference so that the bead diameter is 2
mm (0.08 in) or more.
Tightening torque:
NOTE:
The bolts (2 locations) in the area marked with arrows
are bolts coated with sealing agent. Completely remove
the sealing agent in the threaded portion of the
transmission case and use new bolts that have been
coated with sealing agent.
46 Nm (4.7 kgm / 34 lbft)
LNW25CSH050801

surface of the reverse idle cover for the
transmission case, then install the reverse idle
cover.
5C-37

Tightening torque:
20 Nm (2.0 kgm / 14 lbft)
MFW45DSH005001

surface of the PTO cover for the transmission
case, and then install the PTO cover.
Tightening torque:
37 Nm (3.8 kgm / 27 lbft)
NOTE:
Since sealing agent is applied to the bolts, completely
remove the sealing agent in the threaded portion of the
MFW45DMH001101
28. Install the interlock plate.

29. Set the shift position to neutral, apply ThreeBond
1215 or equivalent to the mating surface of the
control box for the transmission case, then install
the control box.
Tightening torque:
27 Nm (2.8 kgm / 20 lbft)
NOTE:
Since sealing agent is applied to the bolts, completely
remove the sealing agent in the threaded portion of the
5C-38

32. Apply engine oil to the speedometer driven gear
and O-ring and install the speedometer driven
gear. Refer to Vehicle Speed Sensor in this section
for more information on the installation method.
Tightening torque:
20 Nm (2.0 kgm / 14 lbft)
33. Apply engine oil to the O-ring and install the sensor
dummy plug.
Tightening torque:
9 Nm (0.9 kgm / 78 lbin)
34. Apply engine oil to the O-ring and install the drain
plug and O-ring.
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
35. Apply engine oil to the O-ring and install the filler
plug and O-ring.
LNW25CSH052801
30. After completely removing the sealing agent on the

threaded portion of the detent ASM, apply
LOCTITE 242 or equivalent and perform
installation.
Tightening torque:
27 Nm (2.8 kgm / 20 lbft)
Tightening torque:
36. Mount the parking

transmission case.
Tightening torque:
1
MFW75BSH003601
Legend
1. Detent ASM
2. 4th-5th shift arm
3. 6th shift block
4. 1st - reverse shift block
5. 2nd-3rd shift arm
6. 1st - reverse shift arm
31. Remove any old sealing agents, apply ThreeBond
TB1141 to the threaded portion of the reverse
switch within the specified are and install the
reverse switch.
Refer to "Reverse and Neutral Switch" in this
section.
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
brake
bracket
to
the
48 Nm (4.9 kgm / 35 lbft)
37. Install the parking brake ASM.

Refer to "Parking Brake" in Section 4D, Parking
Brake.
38. Apply engine oil to the O-ring, then install the
coupling driver and O-ring.
39. Use a new lock nut, apply engine oil to the seat
surface, then tighten the lock nut using the flange
holder: 9-8529-2101-0.
Tightening torque:
39 Nm (4.0 kgm / 29 lbft)
382 Nm (39.0 kgm / 282 lbft)
After tightening the lock nut at the specified

torque, align the lip area of the nut with the Vgroove at the tip of the shaft. Firmly caulk the
nut in 2 places using a chisel (tip shape: radius
of approximately 1 mm (0.04 in) x 60) so that
the length is 5 mm (0.2 in) or longer (B), and the
gap between the bottom of the V-groove of the
shaft and the nut and lip is 2.5 mm (0.1 in) or
shorter (A).
NOTE:
If any crack is found on the lip section of the nut after
caulking, replace the lock nut and caulk it again.
MIN
5.0mm (0.20 in)
B
MIN
5.0mm (0.20 in)
MAX
2.5mm (0.10 in)
A
MAX
2.5mm (0.10 in)
LNWA5CMH000101
40. Install the parking brake drum and adjust hole

cover fixing bolt.
Tightening torque:
22 Nm (2.2 kgm / 16 lbft)
41. Install the shift block, release bearing, clutch shaft,

and shift fork.
Refer to "Clutch ASM" in Section 5E Clutch.
42. Connect each harness connector.
Neutral switch
Reverse switch
5C-39
5C-40
b
c
d
e
f
l
k
g
o
n
j
i
h
MFWB5CLF000201
Legend
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
27 Nm (2.8 kgm / 20 lbft)

39 Nm (4.0 kgm / 29 lbft)
27 Nm (2.8 kgm / 20 lbft)
39 Nm (4.0 kgm / 29 lbft)
27 Nm (2.8 kgm / 20 lbft)
44 Nm (4.5 kgm / 33 lbft)
26 Nm (2.7 kgm / 20 lbft)
27 Nm (2.8 kgm / 20 lbft)
20 Nm (2.0 kgm / 14 lbft)
37 Nm (3.8 kgm / 27 lbft)
(k)
(l)
(m)
(n)
(o)
(p)
(q)
(r)
9 Nm (0.9 kgm / 78 lbin)

27 Nm (2.8 kgm / 20 lbft)
46 Nm (4.7 kgm / 34 lbft)
20 Nm (2.0 kgm / 14 lbft)
48 Nm (4.9 kgm / 35 lbft)
46 Nm (4.7 kgm / 34 lbft)
39 Nm (4.0 kgm / 29 lbft)
382 Nm (39.0 kgm / 282 lbft)
5C-41
Top Gear Shaft

Components
1
4
5
LNW25CSF000201
Legend
1. Snap Ring
2. Bearing
3. Top Gear Shaft
Disassembly
1. Remove the blocking ring from the top gear shaft.
2. Remove the needle bearing from the top gear
shaft.
Since the needle bearing is a separator type,
be careful not to drop or damage the roller
during disassembly or assembly. Also,
completely remove any installed foreign
material and apply BESCO L2 grease or
equivalent before assembling.
3. Remove the snap ring using snap ring pliers.
4. Needle Bearing
5. Blocking Ring
4. Remove the bearing in the press using the bearing

remover.
LNW25CSH030901
Inspect each part and if there is any wear, damage, or

other abnormalities, repair or replace the defective
parts.
5. Inspect the gear tooth surface, spline section, and
sliding surface at the tip for damage or wear. If any
abnormalities are detected, replace such parts with
new ones.
5C-42
6. Inspect each bearing for the following items. If an

abnormality is detected, replace the bearing with a
new one.
Smoothness of rotation
Abnormal noise
Abnormalities in appearance such as damage,
rust, etc.
Abnormal play in the thrust direction
Discoloration, significant wear, and pitching on
the rolling element and rolling contact of the
needle bearing
Reassembly
1. Firmly fit the bearing with a press, using the
installer: 5-8840-2345-0.
Firmly fit the bearing to make the brim of the
inner race face toward the front side.
5-8840-2345-0
MFW45DSH005201
2. Install the snap ring using snap ring pliers.

3. Mount the needle bearing onto the top gear shaft.
4. Mount the blocking ring onto the top gear shaft.
5C-43
Main Shaft
Components
3
2
4
12
13
14
8
9
15
16
17
10
11
18
19
20
21
24
22
23
25
26
27
28 29
30
MFW45DLF000901
Legend
1. Snap Ring
2. 4th-5th Clutch Hub ASM and Sleeve and 4th
Gear
3. 4th-5th Clutch Hub ASM and Sleeve
4. 4th Blocking Ring
5. 4th Gear
6. Needle Bearing
7. Snap Ring
8. 2nd-3rd Gear and Synchronizer
9. Collar
10. Needle Bearing
11. 3rd Gear
12. 3rd Inside Ring
13. 3rd Outside Ring
14. 3rd Blocking Ring
15. 2nd-3rd Clutch Hub ASM and Sleeve
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
2nd Blocking Ring

2nd Outside Ring
2nd Inside Ring
2nd Gear
Needle Bearing
Main Shaft
Needle Bearing
1st Gear
1st - Reverse Clutch Hub ASM and Sleeve
Reverse Gear
Needle Bearing
Collar
Spacer
Bearing
6th Gear
5C-44
Disassembly
1. Remove the 6th gear.
2. Using the bearing remover and a press, remove
the bearing, spacer, collar, reverse gear, needle
bearing, reverse inside ring, reverse outside ring,
reverse blocking ring, 1st - reverse clutch hub
ASM, sleeve, 1st blocking ring, 1st outside ring, 1st
inside ring, 1st gear, and needle bearing at the
same time.
5. Disassemble the 4th-5th clutch hub ASM and

sleeve.
2
3
MFW45DSH005501
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
LNW25CSH027701
3. Remove the snap ring fixing the 4th-5th clutch hub

ASM using snap ring pliers.
4. Using the bearing remover, remove the 4th-5th
clutch hub ASM and sleeve, 4th blocking ring, 4th
gear, and needle bearing at the same time with a
press.
6. Remove the snap ring fixing the 3rd gear collar

using snap ring pliers.
7. Remove the collar, 3rd gear, needle bearing, 3rd
inside ring, 3rd outside ring, 3rd blocking ring, 2nd3rd clutch hub ASM and sleeve, 2nd blocking ring,
2nd outside ring, 2nd inside ring, 2nd gear and
needle bearing from the main shaft at the same
time with a press.
MFW45DSH005401
MFW45DSH005601

8. Disassemble the 2nd-3rd clutch hub ASM and
sleeve.
5
4
5C-45
(mm (in))
Standard value
Limit for use
2nd gear
63.010 63.029
(2.4807 - 2.4815)
63.069
(2.4830)
1st gear
63.010 63.029
(2.4807 - 2.4815)
63.069
(2.4830)
Reverse Gear
63.010 63.029
(2.4807 - 2.4815)
63.069
(2.4830)
2
3
MFW45DSH005701
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
Inspect each part. If any wear, damage, or other
abnormalities are found, repair or replace the defective
parts.
new one.
Abnormal noise
rust, etc.
10. Inspect the inner diameter of the gear.
Measure the inner diameter of each gear.
Replace the gear if the measured value
exceeds the usage limit.
MFW45DSH005801
11. Inspect fluctuations in the main shaft.

Measure the main shaft for any bending.
Replace the main shaft if the measured value
exceeds the usage limit.
Standard value: 0.015 mm (0.0006 in) Usage
limit: 0.1 mm (0.0039 in)
(mm (in))
Standard value
Limit for use
6th gear
50.009 50.025
(1.9689 - 1.9695)
50.065
(1.9711)
5th gear
(Top gear shaft)
48.009 48.025
(1.8901 - 1.8907)
48.065
(1.8923)
4th gear
55.010 55.029
(2.1657 - 2.1665)
55.069
(2.1681)
3rd gear
63.010 63.029
(2.4807 - 2.4815)
63.069
(2.4830)
MFW45DSH005901
12. Inspect the synchromesh mechanism.
5C-46
Inspect the components and repair minor

stepped wear and damage using an oil stone or
pencil grinder.
LNW25CSH008301
MFW45DSH006001
13. Measure the gap between the blocking ring and

dog gear using a feeler gauge.
Replace the blocking ring (single cone) or
synchronizer ASM (3-cone) if the measured
value exceeds the usage limit.
(mm (in))
Standard value
Limit for use
4th/5th/6th
1.03 - 2.60
(0.041 - 0.102)
0.5
(0.020)
2nd/3rd
1.00 - 2.50
(0.039 - 0.098)
0.5
(0.020)
Legend
1. Blocking ring
2. Outside ring
3. Inside ring
14. Inspect the sliding section, spline section, insert
section, insert groove, etc., of the clutch hub and
sliding sleeve for wear and damage.
15. Measure
the
looseness
(on
the
outer
circumference of the clutch hub) in the spline
rotational direction.
Make replacements if the measured value
exceeds the standard value.
(mm (in))
Standard value
0 - 0.16 (0 - 0.006)
LNW25CSH008201
LNW25CSH045101
16. Measure the gap (A) between the clutch hub and
the budging section of the blocking ring.

Replace the block and clutch hub if the
measured value exceeds the standard value.
5C-47
Fix the main shaft in a vise via a copper plate (1),

etc. When fixing the main shaft, be careful not to
damage it.
(mm (in))
Standard value
3rd-2nd
3.30 - 3.70
(0.130 - 0.146)
5th-4th gear
6th gear
4.30 - 4.70
(0.169 - 0.185)
MFW45CSH000401
1. Assemble the 2nd-3rd clutch hub ASM and sleeve

using the procedure below.
the ball grooves.
LNW25CSH051301
Legend
1. Blocking ring
2. Clutch hub
Reassembly
Clean each part thoroughly.
MFW45DSH006401
it lightly touches the block.
5C-48

1
4. Install the 2nd-3rd gear clutch hub ASM and

sleeve (1), so that each of the 6 claw sections on
the inside ring fit into the 6 holes on the hub, and
then firmly fit them with a press using the installer:
5-8840-2345-0.
2
3
1
2
5
4
3
4
5
6
LNW25CSH038601
2. Apply engine oil to the needle bearing, 2nd gear

thrust surface, and synchro-cone taper section,
face the dog gear upward, then install the 2nd gear
(6) and needle bearing (5) to the main shaft.
3. Install the 2nd gear inside ring (4), 2nd gear
outside ring (3), and 2nd gear blocking ring (2) so
that the claw part of the outside ring fits into the
dog gear hole on the 2nd gear. At this time,
thoroughly apply engine oil to the surfaces of both
the inside ring and outside ring, as well as the
inner diameter of the blocking ring.
LNW25CMH000901
5. Install the 3rd blocking ring (7), 3rd outside ring (6),
and 3rd inside ring (5) so that each of the 6 claw
areas on the inside ring fits into the 6 holes on the
hub. At this time, thoroughly apply engine oil to the
surfaces of both the inside ring and outside ring, as
well as the inner diameter of the blocking ring.
6. Apply engine oil to the needle bearing, 3rd gear
thrust surface, and the synchro-cone taper section,
face the dog gear downward, firmly fit the 3rd gear
(4), needle bearing (3), and collar (2) with a press
so that the claw area of the outer ring fits into the
dog gear hole of the 3rd gear, using the installer: 58840-2345-0.
7. Install the snap ring (1) using snap ring pliers.
NOTE:
Replace the snap ring with a new one if it is deformed
or damaged and make sure that it is installed firmly.
1
2
3
5C-49

4
1
2
5
6
7
3
4
MFW45DSH006501
LNW25CMH001001
8. Assemble the 4th-5th clutch hub ASM and sleeve

using the procedure below.
the ball grooves.
MFW45DSH006401
it touches the block (3) lightly.
9. Apply engine oil to the needle bearing, 4th gear

thrust surface, and the synchro-cone taper section,
face the dog gear upward, and install the 4th gear
(5) and needle bearing (4).
10. Thoroughly apply engine oil to the 4th blocking ring
(3) and install.
11. Align the positions of the 4th-5th clutch hub ASM
and sleeve (2) with the 4th blocking ring groove
and firmly fit them with a press using the installer:
5-8840-2345-0.
12. Install the snap ring (1) using snap ring pliers.
NOTE:
Replace the snap ring with a new one if it is deformed
or damaged. Make sure that it is installed firmly.
5C-50

14. Install the 1st-reverse clutch hub and sleeve (1)
and firmly fit them with a press, using the installer:
5-8840-2345-0.
1
2
3
2
3
LNW25CMH003001
13. Invert the main shaft and install it in a vise.

Apply engine oil to the needle bearing and 1st gear
thrust surface and install the 1st gear (6) and
needle bearing (5) with the dog gear facing
upward.
LNW25CMH004101

15. Apply engine oil to the needle bearing and reverse
gear thrust surface, face the dog gear downward,
and firmly fit the reverse gear (3), needle bearing
(2), and collar (1) with a press, using the installer:
5-8840-2345-0.
5C-51
17. Orient the bearing (1) so that the surface marked A

(4) is on the top, and the surface marked B (3) is
on the bottom, and firmly fit the bearing with a
press, using the installer: 5-8840-2345-0.
4
1
2
1
3
2
MFW45CMH000401
MFW45CMH000301
16. Install the spacer (2).
18. Install the 6th gear.

Install the 6th gear so that the budging section
faces the reverse gear side.
5C-52
Counter Shaft
Components
1
2
4
5
6
MFW45DMF000601
Legend
1. Snap Ring
2. Bearing; Counter Front
3. Counter Shaft ASM
Disassembly
1. Remove the snap ring used for fixing the bearing
by using snap ring pliers.
4. Bearing; Counter Rear

5. Thrust Washer
6. Collar
2. Remove the bearing; counter front using the

bearing remover: 5-8840-2587-0.
5-8840-2587-0
LNW25CSH031101

3. Remove the collar and thrust washer with a press
using the bearing remover.
5C-53
Reassembly
1. Firmly fit the bearing; counter rear with a press
using the bearing installer: 5-8840-2244-0.
5-8840-2244-0
LNW25CSH049001
4. Remove the bearing; counter rear using the

bearing remover: 5-8840-2587-0.
LNW25CSH031401
2. Firmly fit the thrust washer and collar with a press,

using the bearing installer: 5-8840-2244-0.
5-8840-2587-0
5-8840-2244-0
LNW25CSH031201
If wear, damage, or other abnormalities are found in the

disassembled parts, repair or replace the defective
parts.
5. Inspect the cross-section of each gear for
breakage, damage, and wear. If an abnormality is
found, replace the gear with a new one.
new one.
Abnormal noise
rust, etc.
LNW25CSH049101
5C-54
3. Install the bearing: counter front with a press using

the bearing installer: 5-8840-2244-0.
5-8840-2244-0
LNW25CSH031501
4. Install the snap ring for fixing the bearing by using

snap ring pliers.
Select the thickest spring from among the 3
installable springs.
Thickness (mm (in))
Identification color
1.9 (0.075)
Colorless
2.1 (0.083)
Yellow
2.3 (0.091)
Pink
NOTE:
When installing, replace the snap ring with a new one if
it is deformed or damaged. Confirm that it is securely
installed.
5C-55
Control Box
Components
14
13
12
19
15
11
16
10
18
17
20
9
5
6
8
21
26
23
24
28
22
25
27
MFW75CLF000601
Legend
1. Spring
2. Plain Washer
3. Shift Internal Lever
4. Plain Washer
5. Spring
6. Spring Stopper
7. Spring Pin (Spring Stopper)
8. Control Box
9. Detent ASM
10. Oil Seal
11. Washer
12. Select External Lever
13. Link Rod
14. Select Relay Lever
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
O-ring
Bushing
Bolt
Oil Seal
Shift Shaft
Pipe
Power Assist ASM
Neutral Switch
Bushing
O-ring
Plain Washer
Spring Pin (Shift Shaft)
Spring Pin
Select Internal Lever
5C-56
Disassembly
1. Remove the neutral switch and detent ASM.
2. Remove the bolts (3 pieces) fixing the power assist
ASM to the control box and the nut (1 piece)
tightening the shift shaft, and then remove the
power assist ASM.
3. Remove the link rod.
4. Remove the nut fixing the select relay lever, and
then remove the select relay lever, plain washer,
O-rings (2 pieces) and bushings (2 pieces).
5. Using a spring remover, remove the spring pin,
and then remove the select internal lever, select
external lever, and washer.
6. Remove the spring pin (spring stopper) using
pliers.
7. Remove the bolt from the control box and punch
out the spring pin (shift shaft).
8. Pull out the shift shaft, and then remove the spring
stopper, spring (2 pieces), plain washer (2 pieces)
and shift internal lever.
9. Remove the select lever shaft oil seal and shift
lever shaft oil seal from the control box by
wrenching them with a screwdriver, etc.
If wear, damage or other abnormalities are found in the
disassembled parts, repair or replace the defective
parts.
10. Check for wear of the shift lever shaft, looseness
with the control box, and for motion that is not
smooth. Replace if necessary.
Reassembly
1. Using the control box oil seal installer: 5-88402245-0, install the shift lever shaft oil seal and
select lever shaft oil seal on the control box.
Apply grease to the lip section of the oil seal.
2. Apply gear oil to sliding surface and spline section

of the shift shaft. Apply grease to the detent groove
on the spring stopper.
3. Insert the shift shaft into the control box while
assembling the spring stopper, spring (2 pieces),
plain washer (2 pieces) and shift internal lever.
NOTE:
When inserting the shift shaft, be careful not to damage
the oil seal.
4. Align the pin hole on the shift shaft with the pin
hole on the spring stopper, and then tap in the new
spring pin (spring stopper) and spring pin (shift
shaft).
NOTE:
After tapping the spring pin in, approximately 7 mm
(0.28 in) of the head section of the spring pin must
remain.
5. Tighten the bolt.
Tightening torque:
6. Apply grease to the sliding area of the select

external lever. Insert the select external lever and
washer into the control box, install the select
internal lever, and then punch out the new spring
pin.
NOTE:
When inserting the select external lever, be careful not
to damage the oil seal.
7. Insert 2 bushings from the top and bottom into the
control box, assemble an O-ring to the select relay
lever, and then insert them into the control box.
Assemble the O-rings and plain washers into the
select relay lever and then install them using the
mounting nut.
Tightening torque:
5-8840-2245-0
6 Nm (0.6 kgm / 52 lbin)
37 Nm (3.8 kgm / 27 lbft)
8. Install the link rod using the nut.

Tightening torque:
24 Nm (2.4 kgm / 17 lbft)
9. Mount the power assist ASM to the control box and

shift shaft.
Bolt
Tightening torque: 43 Nm (4.4 kgm / 32 lbft)
Nut
Tightening torque:
MFW45DSH007101
83 Nm (8.5 kgm / 61 lbft)
10. Install the detent ASM.

Since the detent ASM is precoated, completely
remove the sealing agent on its threaded area.
Then apply LOCTITE 242 or equivalent on the
threaded area of the detent ASM and install it.
Tightening torque:
28 Nm (2.9 kgm / 21 lbft)

11. Tighten the neutral switch at the specified torque.
Remove the old sealing agent on the switch
threaded area, apply new sealing agent within
the illustrated range, and then assemble.
Sealing agent:
Tightening torque:
ThreeBond 1141 or equivalent

34 Nm (3.5 kgm / 25 lbft)
MFW75BSH002001
Legend
1. Sealing agent coating area (within the half length
of thread)
5C-57
5C-58

b
d
c
e
a
g
MFW75CMF000301
Legend
(a)
(b)
(c)
(d)
28 Nm (2.9 kgm / 21 lbft)

24 Nm (2.4 kgm / 17 lbft)
6 Nm (0.6 kgm / 52 lbin)
83 Nm (8.5 kgm / 61 lbft)
(e)
(f)
(g)
43 Nm (4.4 kgm / 32 lbft)

34 Nm (3.5 kgm / 25 lbft)
37 Nm (3.8 kgm / 27 lbft)
Clutch (MZZ)
Clutch
(MZZ)
TABLE OF CONTENTS
Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2
Description of Function and Operation . . . . . . . 5E-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-3
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-8
Clutch ASM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-9
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-16
Primary Specifications. . . . . . . . . . . . . . . . . . . 5E-20
Clutch Master Cylinder. . . . . . . . . . . . . . . . . . . . 5E-21
Description of Function and Operation . . . . . . 5E-21
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-25
Clutch Booster . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-27
Description of Function and Operation . . . . . . 5E-27
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-30
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-41
List of Tightening Torques . . . . . . . . . . . . . . . . 5E-44
5E-1
5E-2
Clutch (MZZ)
Clutch System
MFWB5EMF000401
Legend
1. Clutch Cover ASM
2. Clutch Disk
Facing dimensions
Engine type
4HK1-TCC
Clutch size
D (mm (in))
d (mm (in))
14 inch
350 (13.78)
220 (8.66)
Clutch (MZZ)
5E-3
Inspection
Remove air out from the clutch system
1
2
3
MFW75ELF000301
Legend
1. Reservoir Tank
2. Brake Pedal
3. Clutch Pedal
1. Pour clutch fluid (BESCO brake fluid super (DOT3)
or equivalent) into the reservoir tank.
CAUTION:
As the amount of clutch fluid is reduced through the air
removal process, check frequently to make sure the
tank is not emptied.
4. Air Bleeder
5. Vinyl Pipe
5E-4
Clutch (MZZ)
MFW75ESH000301
2. Installing the vinyl pipe.

Attach the vinyl pipe to the bleeder screw of the
clutch booster and place the other end of the
pipe into a clear container containing roughly 1/
3 of clutch fluid.
MFW75ESH000401
b. Remove the air.

After pressing the pedal repeatedly, in this
condition, loosen the bleeder with a half turn to
release the air. Tighten the bleeder prior to
releasing the pedal.
Repeat the above procedure until there are no
bubbles in the discharged clutch fluid.
CAUTION:
Make sure clutch fluid does not get low during the
operation.
MFW45ESH004501
3. Air removal work

Fill the cylinder and pipes with clutch fluid.
a. Loosen the bleeder screw and depress on the
clutch pedal repeatedly and tighten the bleeder
screw at the location where the pedal is hardest
to depress.
CAUTION:
Stop the engine and perform under conditions where
the booster does not operate.
MFW75ESH000501
Clutch (MZZ)
5E-5
Clutch pedal free play inspection and adjustment
Adjustment of the clutch pedal free play
Inspection of clutch pedal free play
If the clutch pedal free play exceeds specifications,

adjust the gap between the tip of the push rod and the
piston.
1. Remove the hook section of the clutch pedal return
spring from the slot of the clutch pedal ASM.
Refer to "Pedal Box ASM" in Section 4A2 Brake
Control System (Air Over).
2. Loosen the lock nut of the clutch master cylinder
push rod.
3. Turn until the push rod contacts the piston.
4. From this position, turn it back 2/5 - 4/5 turn, and
check the gap between the tip of the push rod and
the piston is in the specification.
1. Lightly push in the clutch pedal using your hand

until resistance to movement is felt in order to
check the clutch pedal free play.
Clutch pedal free play
60 - 80 mm (2.36 - 3.15 in)
The gap between the tip of the

push rod and the piston
1
0.5 - 1.0 mm
(0.020 - 0.039 in)
5. Firmly tighten the lock nut and re-attach the return

spring.
6. Inspect the gap between the tip of the push rod
and the piston is in the specification.
Refer to the previously described inspection
procedure for clutch pedal free play.
MFW75ESH000601
Legend
1. Clutch pedal free play
1
HFW85ESH001201
Legend
1. Lock nut
2. 0.5 - 1.0 mm (0.020 - 0.039 in)
3. Push rod
4. Clutch pedal
5E-6
Clutch (MZZ)
Clutch ASM free play inspection and adjustment
Adjustment of the clutch ASM free play
Inspection of clutch ASM free play
If the clutch ASM free play is not within the specified

range, stop the engine and adjust the push rod at the
clutch booster.
1. Remove the clutch booster return spring.
2. Loosen the push rod lock nut.
3. While pushing out the push rod, turn until it
becomes firm.
4. From this position, loosen the push rod back
according to the number of turns shown below.
1. Block the wheels, make sure that the parking

brake is set and with the engine idling, depress the
clutch pedal all the way in.
2. Put into 1st gear, slowly release the clutch pedal to
determine the distance (a) between the clutch
pedal stopper and the pedal box just prior to
engagement of the clutch.
Distance (a) between the pedal
stopper and pedal box when
clutch engages
38 mm (1.50 in)
or more
Number of reversing turns of the clutch booster push

rod
Assembly Standard
5. Firmly tighten the lock nut and re-attach the return

spring.
6. Inspect the clutch ASM free play is in the
specification.
Refer to the previously described inspection
procedure for clutch ASM free play.
5 1/4 - 5 3/4
MFW85ESH000201
Legend
1. Pedal box
2. Clutch pedal
2
1
MFW45ESH009301
Legend
1. Lock nut
2. Push rod
Clutch (MZZ)
Adjust the clutch switch
1. Remove the connector of the clutch switch.
2. Loosen the lock nut.
3. Adjust the amount of protrusion of the push rod to
the range in the following table.
The amount of protrusion of the clutch switch push
rod
Without PTO
0.4 - 1.2 mm (0.016 - 0.047 in)
With PTO
0 - 0.4 mm (0 - 0.016 in)
4. Tighten the lock nut.

Tightening torque
Nm (kgm / lbin)
13(1.3 / 113)
2
5
1
MFW75ESH002401
Legend
1. Clutch switch
2. Threaded portion
3. Lock nut
4. Push rod
5. Push rod extension amount
6. Clutch pedal
5E-7
5E-8
Clutch (MZZ)
Special Tool
Illustration
1-8525-3012-0
Clutch pilot aligner
1852530120
1-8525-3026-0
Release lever aligner
1852530260
Clutch (MZZ)
5E-9
Clutch ASM
Components
1
3
2
9
25
24
23
21
22
11
10
12
13
20
19
18
17
16
15
15
14
16
MFWB5ELF000501
Legend
1. Clutch Disk
2. Pressure Plate
3. Clutch Cover ASM
4. Spring Seat (Pressure Plate Side)
5. Clutch Spring
6. Spring Seat (Clutch Cover Side)
7. Strap Plate
8. Clutch Cover Set Bolt
9. Clutch Cover
10. Lock Plate
11. Support Nut
12. Check Hole Cover
13. Clutch Shaft
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Key
Dust Seal
Needle Bearing
Shift Fork
Washer
Shift Fork Set Bolt
Release Bearing ASM
Lever Pin (for Lever Support)
Lever Support
Return Spring
Release Lever
Lever Pin (for Release Lever)
5E-10
Clutch (MZZ)
Disassembly
1. After removing auxiliary components mounted to
the transmission and the clutch booster push rod,
support and stabilize the transmission using a
transmission jack.
2. Remove the flywheel housing installation bolts and
pull the transmission toward the rear of the vehicle.
Fix the pressure plate and clutch cover in place

in 4 locations using dummy bolts for fixation of
the pressure plate, nuts, and washers.
Dummy bolt (1)
M10 1.25
L = 150 mm (5.91 in) 4 pieces
1
MFW45ESH000101
3. Remove the clutch cover ASM.

Insert the clutch pilot aligner in the clutch disk.
(Prevents dropping of the clutch disk.)
Special Tool
MFW45ESH000301
Remove clutch cover set bolts on diagonal from

each other, in order, referring to the diagram.

Parts number
Clutch disk spline small

diameter
1-8525-3012-0
30.836 mm (1.2140in)
9 1
11
12
2 10
MFW75ESH001601
MFW45ESH000201
Legend
1. Clutch pilot aligner
Clutch (MZZ)
5E-11
4. Remove the clutch disk.
MFW45ESH000701
MFW45ESH000401
5. Remove the strap plate.

Remove the hexagon socket head bolts on the
side of the pressure plate and separate the
strap plate and pressure plate. As the clutch
cover side is attached using rivets (1), it is not
to be disassembled.
MFW45ESH000601
6. Remove the lock plate.

7. Using a dummy bolt or a press and a block of
wood, remove the support nut and separate the
clutch cover and the pressure plate.
CAUTION:
Make sure to compress the clutch spring for performing
the work.
8. Remove the clutch spring.

9. Remove the spring seat on the clutch cover side
and the pressure plate side.
10. Remove the lever pin (for lever support).
11. Remove the lever support.
12. Remove the return spring.
13. Remove the lever pin (for release lever).
14. Remove the release lever.
15. Remove the release bearing ASM.
16. Remove the shift fork set bolt.
17. Tap the opposite side of the clutch shaft's shaft
lever with a copper rod.
18. When the key is released from the shift fork,
remove the key and pull out the shaft.
5E-12
Clutch (MZZ)
2. Inspect the pressure plate for cracks, scratches
and deformation.
19. Remove the shift fork.

1
2
Amount of deformation
mm (in)
Limit for use
0.3 (0.0118)
When polishing or sanding is required as part of

a repair, do not exceed the limit of use.
3
4
MFWB5ESH001001
Legend
1. Shift fork
2. Clutch shaft
3. Set bolt
4. Key
20. Remove the dust seal.
21. Remove the needle bearing.
MFW45ESH001101
3. Measure the friction of the pressure plate.
Inspection of clutch cover ASM

1. Inspect the clutch cover ASM.
Determine the friction of the contact surface
between the support nut and clutch cover.
Thickness of the pressure plate
mm (in)
Size
14 inch
Nominal
Dimension
31.0 (1.22)
Limit for use
30.0 (1.18)
MFW45ESH001001
In addition, inspect the whole clutch cover for

any problems such as abnormal wear and
cracks.
MFW45ESH001201
Clutch (MZZ)
Inspect the clutch disk
1. Inspect the damper spring and facing.
Inspect the damper spring for breakage and
wear and tear.
Inspect the facing surface for cracks, surface
hardening due to loss of combustion, oil
deposits, and loosening of rivets.
5E-13
Insert a pilot aligner in the clutch disk, support

both ends horizontally. For 14 inch from the
outer diameter of the clutch disk, make
measurement at positions 5 mm (0.197 in).
Amount of fluctuation of
the clutch disk
mm (in)
Size
14 inch
5 mm (0.197 in) position
Nominal Dimension
0.8 (0.031) or less
Limit for use
1.1 (0.043)
MFW45ESH001301
2. Measure the thickness of the facing.

Measure the rivet depth at the facing surface.
Measure both surfaces.
Amount of sinking of rivets
mm (in)
Size
14 inch
Nominal Dimension
2.0 - 2.6 (0.079 - 0.102)
Limit for use
0.2 (0.0078)
MFW45ESH001501
4. Measure the play in the spline rotational direction

of the clutch disk.
Clean the spline and insert it onto the top gear
shaft. Measure the circumference of the clutch
disk with a surface gauge.
Play in the rotational direction
MFW45ESH001401
3. Measure the fluctuation in the clutch disk.
mm (in)
Assembly Standard
Limit for use
1.0 (0.039) or less
2.0 (0.078)
5E-14
Clutch (MZZ)
CAUTION:
When polishing or sanding as part of a repair, do not
exceed the limit of use.
MFW45ESH001601
5. Inspect the spline section of the clutch disk.

Inspect for any signs of rust on the spline. Also,
inspect the top of the top gear shaft spline to
see if it slides smoothly.
Repair minor stepped wear on the top gear
shaft spline by polishing or sanding it with an oil
stone.
MFW45ESH001801
7. Inspect the pilot bearing for wear and abnormal

noise.
CAUTION:
Do not clean nor wash because it is grease sealed.
MFW45ESH001701
6. Inspect the flywheel for cracks and scratches, and

measure the amount it is worn.
For removing, installing, etc. of the flywheel,
refer to "Flywheel" in Section 1B Engine
Mechanical 4HK1.
MFW45ESH001901
8. Inspect the wear on the contact surfaces of the

shift fork.
Wear
Clutch nominal size
mm (in)
Size
14 inch
Nominal Dimension
43.0 (1.69)
Limit for use
44.0 (1.73)
mm (in)
Limit for use
0.5 (0.020)
CAUTION:
Repair minor wear by polishing or sanding with the use
of an oil stone.
Clutch (MZZ)
10.
5E-15
Inspect the release bearing to see if it slides

smoothly on the clutch housing.
2
1
3
MFWB5ESH001101
Legend
1. Release bearing ASM
2. Shift fork
3. Thrust race (shift fork contact surface)
9. Inspect the release bearing for wear and abnormal
sounds.
Inspect the release bearing for looseness,
abnormal sounds, damage and nonsmooth
rotation.
Inspect the release lever and shift fork contact
surfaces of the release bearing for wear.
Inspect the release bearing inner diameter for
wear.
If an abnormality is detected, replacement of
release bearing is needed.
CAUTION:
As it is sealed with grease, do not clean nor wash.
MFWB5ESH000301
Legend
11. Inspect the clutch shaft for stepped wear,
disproportionate wear and for looseness between
the clutch shaft and the needle bearing.
External shape of the
clutch shaft
mm (in)
Nominal Dimension
Limit for use
25.0 (0.984)
24.5 (0.965)
CAUTION:
If there is a lot of wear or looseness, replace both the
shaft and the bearing.
MFWB5ESH001401
MFW85ESH001201
5E-16
Clutch (MZZ)
Reassembly
1. Apply a thin layer of grease (ONE LUBER MO
No.2 (molybdenum disulfide) or equivalent) to
each of the lever pin sliding surface.
CAUTION:
When polishing or sanding the pressure plate for repair,
insert a washer equivalent to the amount of material
removed for installation.
Thickness of the inserted washer
mm (in)
1.0 or (0.039) less
MFW45ESH002501
Legend
1. Grease coating
2. After installing the lever support and return spring
onto the release lever, install the lever pin (for lever
support).
3. Install the release lever ASM to the pressure plate
using the lever pin (for release lever).
MFW45ESH002701
Legend
1. Clutch spring
2. Washer
3. Spring seat
5. Apply a thin layer of grease (ONE LUBER MO
No.2 (molybdenum disulfide) or equivalent) to the
contact area for the support nut on the clutch
cover.
MFW45ESH002601
Legend
1. Grease coating
4. Install the spring seat and clutch spring to the
pressure plate.
MFW45ESH002801
6. Attach the clutch cover to the pressure plate using

a press or a dummy bolt.
a. Method for using a press
Clutch (MZZ)
Compress the clutch cover with a press until
the threaded portion of the lever support
protrudes above the upper surface of the
cover.
Temporarily tighten the support nuts to an
equal tightness.
5E-17
Tighten the pressure plate side using a

hexagon socket head bolt.
8. Apply grease (variant grease S or equivalent) to
the spline grease groove.
9. Insert the clutch pilot aligner in the clutch disk.
Special Tool
mm (in)
Parts number
Clutch disk Spline small

diameter
1-8525-3012-0
30.836 (1.2140)
MFW45ESH002901
b. Method for using a dummy bolt

Screw the dummy bolt into the pressure
plate.
Fix the dummy bolt in place using a wrench
and tighten the nut until the threaded portion
of the lever support protrudes above the
upper surface of the clutch cover.
Temporarily tighten the support nuts to an
equal tightness.
MFW45ESH003201
10. Insert the clutch pilot aligner integrated with the

clutch disk into the pilot bearing.
MFW45ESH003001
7. Mount the strap plate to the pressure plate.

Tightening torque
14 inch
Nm (kgm / lbft)
44 ( 4.5 / 33)
MFW45ESH003301
Legend
1. Clutch pilot aligner
11. Install the clutch cover ASM onto the flywheel.
Align the clutch cover knock hole (as shown in
the diagram) with the flywheel knock pin.
5E-18
Clutch (MZZ)
Slowly and equally tighten the clutch cover set

bolts in a diagonal order as shown in the
diagram.
Tightening torque
Nm (kgm / lbft)
14 inch
44 ( 4.5 / 33)
Place the release lever aligner on the flywheel

housing, and adjust the support nut so that
there is no gap between the center of the
release lever aligner and the lever.
Dimension L between the end surface of the
flywheel housing and the end surface of the
release lever (Error margin for misalignment:
0.3mm (0.0118 in))
Special Tool
Release lever aligner
9 1
mm (in)
Clutch size
Parts number
L dimension
14 inch
1-8525-3026-0
29 (1.14)
(center indent section)
11
12
2 10
MFW75ESH001701
12. When installing a new clutch cover ASM, be sure

to remove the bolt for protecting the pressure plate
after installing the clutch cover ASM to the
flywheel.
MFW45ESH003501
Legend
1. Release lever aligner
15. Fix the support nut into place with the lock plate.
Tightening torque
14 inch
MFW45ESH003401
Legend
1. Clutch cover
2. Pressure plate
3. Pressure plate protection bolt
13. Pull out the clutch pilot aligner.
Do not strike the clutch pilot aligner with a
hammer, etc., to remove it.
14. Adjust the height of the release lever.
Nm (kgm / lbin)
13 ( 1.3 / 113)
Clutch (MZZ)
5E-19
18. Insert the clutch shaft into the clutch housing and
install the key.
1
2
1
3
MFW45ESH003601
Legend
1. Lock plate
MFWB5ESH001001
16. Tap the needle bearing into the clutch housing until
it reaches its specified position.
Direct the marking of the needle bearing toward
the insertion side.
17. Fill the needle bearing and the space between the
needle bearing and the dust seal with grease
(BESCO L-2, L-3 grease or equivalent). Orient the
dust seal lip towards the outside to install it in its
specified position.
Legend
1. Shift fork
2. Clutch shaft
3. Set bolt
4. Key
19. Install the clutch shaft to the shift fork.
Install the shift fork matched to the clutch shaft
key.
Align the hole of the shift fork set bolt with the
hole of the clutch shaft and tighten the set bolt
at the specified torque.
Tightening torque
Nm (kgm / lbin)
13(1.3 / 113)
MFWB5ESH001201
Legend
1. Needle bearing
2. Dust seal
20. Install the release bearing ASM to the clutch

housing.
Insert the release bearing ASM into the clutch
housing.
Apply 1.5 g (0.053 oz) to 2.5 g (0.088 oz) of
grease (ONE LUBER MO No.2 (molybdenum
disulfide) or equivalent) to the release bearing
contact surfaces (2 places) of the shift fork (as
shown in the diagram).
Apply 1.0 g (0.035 oz) of grease (ONE LUBER
MO No.2 (molybdenum disulfide) or equivalent)
to the release bearing return spring contact
surfaces (2 places) of the shift fork (as shown in
the diagram).
Do not get grease on the release BRG and
clutch housing sliding areas.
Confirm that the release bearing return spring is
firmly assembled to the shift fork.
5E-20
Clutch (MZZ)
1
1
MFW95ESH000301
Legend
1. Release bearing return spring
MFWB5ESH001301
Legend
21. Apply grease (variant grease S or equivalent)
thinly and as evenly as possible to whole
circumference of the top gear shaft within about 40
mm (1.57 in) from tip of spline.
(Do not need to apply grease to the tooth crevices
of spline).
22. Mount the transmission ASM.
23. Support the transmission using a transmission
jack, and while matching the inclination of the
engine, slowly push the transmission into place
and install it in place using a bolt.
Tightening torque
14 inch
Nm (kgm / lbft)
44(4.5 / 33)
Item
Clutch size (nominal)
Specifications
14 inch
Clutch type
Dry single plate coil spring type strap drive
Control type
With hydraulic clutch booster
Facing dimensions
(External internal diameter thickness number of plates) (mm (in))
Clutch spring set load (N (kg / lb))
Diameter stroke (mm (in)) of clutch booster
power cylinder
Engine type
350 (13.78) 220 (8.66) 4.5 (0.177) - 2 plates

9905 (1010 / 2227)
70 (2.76) 35.8 (1.41)
4HK1-TCC
Clutch (MZZ)
5E-21
Clutch Master Cylinder

Cross Section A-A
MFW85ELF000101
Legend
1. Cap
2. Diaphragm Gasket
3. Dust Cover
4. Snap Ring
5.
6.
7.
8.
Piston ASM
Gasket
Stopper Bolt
Reservoir Tank
5E-22
Clutch (MZZ)
Components
1
2
7
6
4
5
MFW75ELF001001
Legend
1. Cap
2. Diaphragm Gasket
3. Piston ASM
4. Snap Ring
Removal
1. Disconnect the clutch hose from the clutch master
cylinder.
Loosen the nut on the upper side of the clutch
hose (as shown in the diagram).
As necessary, loosen the installation nut (2) to
remove the air hose clamp (1).
CAUTION:
When removing the hose, make sure not to spill
clutch fluid on the front bumper, etc.
5. Dust Cover
6. Gasket
7. Stopper Bolt
Protect the disconnected section from intrusion of

dust or filth.
Clutch (MZZ)
1
MFW75ESH001801
2. Remove the clutch master cylinder installation bolt

(1) behind the clutch pedal (2).
5E-23
MFW75ESH002001
Disassembly
1. Remove the dust cover.
2. Fix the cylinder body in a vise, and while pressing
the piston with a Phillips-head screwdriver, etc.,
remove in the order of the stopper bolt, gasket and
snap ring.
3. Remove the piston ASM.
4. Remove the cap.
5. Remove the diaphragm gasket from the cap.
Inspection
1. Inspect the lip area of the primary cup and
secondary cup for damage, as well as the sliding
surface of the piston and cylinder for wear and
damage.
2
MFW75ESH001901
3. Remove the clutch master cylinder.

Suspend the clutch master cylinder slightly to
loosen the fitting between the pedal box
positioning pin (2) and the clutch master
cylinder positioning hole (3).
Remove the clutch master cylinder towards the
downward direction without causing any load
on the push rod (1).
CAUTION:
Use clutch fluid for cleaning.
Do not remove the reservoir tank and the clamp.
5E-24
Clutch (MZZ)
2
1
MFW75ESH002501
2. Measure the external diameter of the piston and

the gap between the piston and cylinder body.
mm (in)
Nominal
Dimension
Assembly
Standard
Limit for
use
19.05
(0.7500)
18.96
(0.7464)
0.04 - 0.125
(0.0016 - 0.0049)
0.15
(0.0059)
Gap
MFW75ESH002601
Legend
1. Slit area
2. Cylinder body
3. Return spring
Legend
1. Secondary cup
2. Primary cup
3. Return spring
4. Piston
External
diameter
of piston
Reassembly
1. Attach the diaphragm gasket to the cap.
2. Install the cap to the reservoir tank.
3. Coat the inner surface of the cylinder body, the
outer surface of the piston and the cup with clutch
fluid (BESCO brake fluid super (DOT3)).
4. Insert the piston ASM from the side of the return
spring into inside the cylinder body.
Align the stopper bolt installation hole of the
cylinder body with the direction of the piston slit
portion.
5. Fix the cylinder body in a vise, and mount the

stopper bolt via the gasket while pressing the
piston with a screwdriver, etc.
CAUTION:
Install the stopper bolt after confirming that the
stopper bolt installation hole is properly aligned with
the direction of the piston slit portion.
Be careful so that the bolt does not touch the valve
rod or the piston when installing the stopper bolt.
The stopper bolt may come in contact with the valve
rod if the piston is not sufficiently pushed into place.
The stopper bolt may come in contact with the
piston if the piston is pushed in too far.
Tightening torque
Nm (kgm / lbin)
3 ( 0.3 / 26)
6. Fit the snap ring into the groove of the cylinder

body while pressing the piston.
7. Install the dust cover.
Clutch (MZZ)
5E-25
2. Tighten the clutch master cylinder installation bolt

from the cabin side.
Tightening torque
Nm (kgm / lbft)
64 ( 6.5 / 47)
MFW75ESH002701
Legend
1. Valve rod
2. Stopper volt installation position
3. Slit portion
4. Snap ring
5. Dust cover
Installation
1. Install the clutch master cylinder ASM.
Align the pedal box positioning pin (2) with the
clutch master cylinder positioning hole (3).
Align the tip of the push rod (1) with the center
indent section of the piston.
Prevent load from being applied on the push
rod (1).
1
MFW75ESH001901
Legend
1. Bolt
2. Clutch pedal
3. Install the clutch hose to the clutch master cylinder
ASM.
Tightening torque
Nm (kgm / lbft)
26 ( 2.7 / 20)
4. Attach the air hose clamp. (if the air hose clamp is
removed))
5. Remove air from the clutch system.
Refer to "Clutch System" in this section.
MFW75ESH002001
5E-26
Clutch (MZZ)
MFW75ESH000501
6. Adjust the gap between the piston and push rod.

After adjusting, check to make sure that the
amount of play in the clutch pedal is within
specifications.
MFW75ESH002301
Legend
1. Lock nut
2. Clearance between piston and push rod
3. Push rod
4. Clutch pedal
mm (in)
Item
Dimensions
19.05 (0.7500)
Cylinder internal diameter

Maximum stroke
38 (1.50)
Maintenance standards table

mm (in)
Item
Piston external diameter
Gap between piston and cylinder
Nominal Dimension
Assembly Standard
Limit for use
19.05 (0.7500)
18.96 (0.7464)
0.04 - 0.125 (0.0016 - 0.0049)
0.15 (0.0059)
Clutch (MZZ)
5E-27
Clutch Booster
12
11
13
10
14
MFW45EMF000101
Legend
1. Relay Piston (Valve Piston Section)
2. Poppet Valve
3. Poppet Spring
4. Cylinder Body
5. Hydraulic Piston
6. Piston Cup Gasket
8.
9.
10.
11.
12.
13.
14.
Oil Seal
Return Spring
Power Piston
Push Rod
Cup
Cylinder Shell
Relay Piston (Relay Piston Section)
Clutch booster primary specifications

Clutch size
14 inch
Engine type
4HK1-TCC
Power piston diameter stroke
(mm (in))
70 (2.76) 35.8 (1.41)
Hydraulic piston diameter
(mm (in))
19.05 (0.7500)
Push rod diameter
(mm (in))
8 (0.31)
Relay piston section diameter
(mm (in))
16 (0.6299) 3.6 (0.142)
Valve piston section diameter
(mm (in))
23.0 (0.925)
5E-28
Clutch (MZZ)
Components
12
11
6
9
10
15
18
27
24
23
22
21
20
17
13
16
19
25
28
14
31
26
32
33
30
29
MFW45EMF000201
Legend
2. O-ring
3. Relay Piston
4. Spring
5. O-ring
6. Upper Valve Body
7. Poppet Valve
8. Poppet Spring
9. Gasket
10. Connector
11. Collar
12. O-ring
13. Cylinder Shell
14. Nut, Washer
16. Piston Plate
17. O-ring
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Push Rod
Snap Ring
Washer
O-ring
Retainer ASM
Piston Cup Gasket
Retainer
Spring
O-ring
Cylinder Body
Spring Pin
Push Rod
Guard
Hydraulic Piston
Piston Cup Gasket
Piston Cup Gasket
Clutch (MZZ)
5E-29
Clutch booster
MFW45EMF000301
Legend
1. Clevis Pin
2. Return Spring
3. Clutch Booster
Removal
1. Remove the clevis pins for the air pipe, oil pipe,
and push rod and the clutch booster installation
bolt and remove the clutch booster.
4. Air Pipe
5. Oil Pipe
2. Plug the removed pipes so that foreign material

does not get into them.
MFW45ESH005801
5E-30
Clutch (MZZ)
Disassembly
1. After removing dirt and dust from the surface of the
clutch booster, loosen the air bleeder screw of the
relay valve and remove the oil through the oil fill
opening.
3. Remove the connector from the upper valve body

first, and then the gasket from the internal
circumferential groove of the upper valve body.
Next, remove the springs and poppet valves from
inside the upper valve body. Remove the collars
and O-rings from the pipe insertion area.
MFW45ESH005901
Legend
1. Bleeder screw
2. Fix the stand for disassembly and assembly in a
vise, mount the clutch booster, and remove the
guard and fluid system connector.
Special Tool
Stand for disassembly
and assembly:
MFW45ESH006101
4. When three screws are removed, the upper valve

body can be separated from the cylinder body.
Remove the O-rings from the groove of the upper
valve body using a special needle.
Special Tool
Needle: 910-21200 (BOSCH part number)
(70) 910-10691
(BOSCH part number)
(90) 910-10690
(BOSCH part number)
MFW45ESH006201
MFW45ESH006001
Legend
1. Guard
5.
6.
7.
8.
9.
Remove the spring.

Remove the O-ring.
Remove the collar.
Remove the O-ring.
Remove the relay piston from the cylinder body.
Remove the O-rings in the relay piston and piston
cup gasket using a special needle.
Clutch (MZZ)
Special Tool
5E-31
13. By pulling up the push rod while holding down the

tabs on the cylinder shell, the piston plate ASM
can be removed from the cylinder shell ASM.
MFW45ESH006501
MFW45ESH006301
10. Remove the cylinder shell installation bolt and

separate the cylinder body and cylinder shell.
14. Add a special socket to a vise stand, insert the

push rod into the socket and fix it in place. Next,
remove the nut and then the piston plate and Orings.
Special Tool
Socket: 910-22110 (BOSCH part number)
MFW45ESH006401
11. Remove the O-rings from the installation area of

the cylinder shell.
12. Remove the spring.
MFW45ESH006601
15. Use a special pliers to remove the snap ring. Next,

remove the washer, retainer ASM, piston cup
gasket, and retainer in that order from inside the
cylinder body.
16. Remove the retainer ASM and O-rings with a
special tool needle.
Special Tool
Pliers: 910-21970 (BOSCH part number)
5E-32
Clutch (MZZ)
2. During assembly, use a repair kit and replace the
rubber parts.
If there is no other choice but to re-use the rubber
parts, clean them in clutch fluid and inspect them
thoroughly.
3. Measure the gap between the external diameter of
the relay piston and the valve body.
Piston external diameter
mm (in)
Nominal Dimension
Limit for use
16.0 (0.6299)
15.93 (0.6271)
Gap between relay piston and body
MFW45ESH006701
17. Remove the hydraulic piston from the cylinder

body.
18. Using a special tool needle, remove the piston cup
gasket from the hydraulic piston.
19. Remove the spring pin inserted in the intake and
exhaust path of the cylinder body.
mm (in)
Assembly
Standard
Limit for
use
Relay piston section
0.04 - 0.09
(0.0016 - 0.0035)
0.11
(0.0043)
Valve piston section

(23.5 (0.925))
0.1 - 0.25
(0.0040 - 0.0098)
0.3
(0.1181)
MFW45ESH006901
MFW45ESH006801
Inspection
CAUTION:
After cleaning the disassembled parts well using
cleaning fluid, inspect each of the parts thoroughly.
1. In particular, visually inspect the following areas for
wear, damage, deformation or other abnormalities.
If an abnormality is found, repair or replace the
part.
Each spring
Each piston, shell
Valve body, cylinder body
Legend
1. External diameter of piston
4. Measure the gap between the external diameter of
the hydraulic piston and the cylinder.
Piston diameter
mm (in)
Nominal dimension
Limit for use
19.05 (0.7500)
19.01 (0.7484)
Gap between piston and cylinder
mm (in)
Assembly standard
Limit for use
0.01 - 0.06 (0.0004 - 0.0023)
0.08 (0.0031)
Clutch (MZZ)
MFW45ESH007001
5. Inspect the springs for rust and scratches.

6. Measure the free length of each of the springs.
Refer to primary specifications.
MFW45ESH007101
Legend
1. Free length
7. Measure the mount load of each of the springs.
Refer to primary specifications.
5E-33
MFW45ESH007201
5E-34
Clutch (MZZ)
Reassembly
CAUTION:
Apply grease to the locations shown in the table and
diagram below.
Grease type
Application locations
Silicon grease
Cylinder body (No.27), relay valve area, inside surface of the

valve piston side
Relay piston (No.3) valve piston area
Entire surface of O-rings (No.2)
Air master paste

(Silicon grease can be used as an
alternative)
Rubber grease
(Silicon grease can be used as an
alternative)
Inside surface of hydraulic piston area of cylinder body (No.27)

Inside surface of relay valve side of relay valve area of cylinder
body (No.27)
Entire surface of hydraulic piston (No.31)
Apply a sufficient amount of grease to the piston grease groove.
Piston cup gasket (No.32, 33) piston cup gasket (No.23)
Entire surface of push rod (No.18, 29) tip, O-ring (No.21)
Entire surface of the relay piston (No.3) relay piston area and
piston cup gasket (No.1)
Installation groove of the guard (No.30) on the tip of the cylinder
body (No.27)
Contact surface of push rod (No.29) of guard (No.30)
Entire surface of piston cup gasket (No.15)

Inside of cylinder shell (No.13)
Entire surface of O-rings (No.5, 12, 17, 26)
Entire surface of gasket (No.9)
Clutch (MZZ)
5E-35
2
2
2
2
3
2
1
3
2
3
MFWB5ELF000101
Legend
1. Silicon grease
2. Air master paste
3. Rubber grease
5E-36
Clutch (MZZ)
1. Apply a thin layer of rubber grease to the cylinder

area of the cylinder body.
1
2
3
4
5
2
MFW45ESH007501
MFW45ESH007301
Legend
1. Cylinder body
2. Rubber grease
2. Apply rubber grease to the O-ring groove and
piston cup gasket and attach the O-ring.
4. After coating the hydraulic piston with rubber

grease, use a special tool to mount the piston cup
gasket back to back.
Special Tool
2
MFW45ESH007401
Legend
1. O-ring
2. Retainer ASM
3. Insert the retainer ASM and washer in this order
into the power cylinder of the cylinder body, and
install the snap ring using a special tool.
Special Tool
Snap ring pliers:
Legend
1. Snap ring
2. Washer
3. Retainer ASM
4. Piston cup gasket
5. Retainer
6. Cylinder body
910-21970
(BOSCH part number)
CAUTION:
Make sure to assemble the piston cup gasket and
retainer ASM in the correct direction.
Cup insert guide

(fluid pressure side):
910-23280
(BOSCH part number)
Cup insert guide

(atmosphere side):
910-23281
(BOSCH part number)
Clutch (MZZ)
5E-37
7. Assemble the piston cup gasket onto the external

circumference of the piston plate and the O-rings
into the internal circumference grooves.
1
MFW45ESH007601
Legend
1. Cup inserting tool
2. Cup
3. Piston
MFW45ESH007801
5. Apply rubber grease to the piston cup gasket lip

area and the external circumference of the piston,
and install the hydraulic piston to the cylinder body.
CAUTION:
Pay attention to the direction when mounting the
hydraulic piston.
Legend
2. Piston plate
3. O-ring
8. Add a special socket to the vise stand, insert the
push rod into the socket from the hydraulic piston
side and hold down the adapter area. Next, put the
piston plate into the adapter and tighten the nut.
Tightening torque
Nm (kgm / lbft)
25 (2.5 / 18)
Power Piston
Side
Push Rod
Side
MFW85ESH000301
Legend
1. Grease groove
4. Piston
6. Coat the external circumference of the piston
plate, the external circumference and lip area of
the piston cup gasket, the O-rings, and internal
surface of the cylinder shell with air master paste.
MFW45ESH007901
9. After tightening the nut, tap the mesh area of the

nut with a punch to prevent it from loosening.
Punch interval
180 - 2 locations
5E-38
Clutch (MZZ)
MFW45ESH008001
10. Place a special work platform on the vise stand,

place the shell ASM on it, and apply air master
paste to the sliding surfaces of the power piston.
11. Insert the piston plate inside the shell ASM and
attach the spring on top of the piston plate.
Special Tool
Plate stand: 910-10691 (BOSCH part number)
MFW45ESH008101
12. Assemble the O-rings to the cylinder body, align

the alignment marks that were made during
disassembly, and install to the shell ASM.
Tightening torque
Power piston diameter 70
Nm (kgm / lbft)
18 (1.8 / 13)
MFW45ESH008201
13. Using a special tool, mount the piston cup gasket

center aligned to the relay piston.
Special Tool
Cup insert guide
(fluid pressure side):
910-24905
(BOSCH part number)
Cup insert guide

(atmosphere side):
910-24902
(BOSCH part number)
MFW45ESH008301
Clutch (MZZ)
5E-39
14. Coat the O-ring assembly area with silicon grease

and the piston cup gasket assembly area with
rubber grease and assemble the O-rings.
MFW45ESH008601
MFW45ESH008401
15. Apply rubber grease to the relay piston insert area

of the cylinder body and install the relay piston.
18. Install the poppet valve and the spring onto the
upper valve body and next, coat the gasket with air
master paste and assemble the connector.
Tightening torque
Nm (kgm / lbft)
25 (2.5 / 18)
MFW45ESH008501
16. Apply air master paste to the upper valve body and
assemble the O-rings. Next, assemble the O-rings
and collar for the pipe insertion area.
17. Place the spring on top of the relay piston and
align the upper valve body with the pipe position
and mount the upper valve body.
Tightening torque
Nm (kgm / lbin)
5 (0.5 / 43)
MFW45ESH008701
5E-40
Clutch (MZZ)
19. Install springs into the intake and exhaust paths at

the tip of the cylinder body, apply rubber grease to
the guard installation groove, and install the guard.
BESCO L-2, L-3 grease or equivalent
1
MFW45ESH008801
20. Apply rubber grease to tip of the push rod and

push rod contact surface of guard and install the
push rod.
Legend
1. Grease coating
3. Mount the air hoses and oil pipes.
4. Remove air from the clutch system.
Installation
1. Mount the clutch booster.
Tightening torque
MFW45ESH009101
Nm (kgm / lbft)
Transmission - Bracket
(installation bolt)
53 (5.4 / 39)
Clutch booster - Bracket

(installation nut)
26 (2.7 / 20)
MFW75ESH000501
5. Adjust the length of the push rod.

Number of reversing turns of the clutch booster push
rod
Clutch
MFW45ESH008901
2. Apply grease to the clevis pin and assemble it to

the clutch shaft lever.
Assembly Standard
14 inch
5 1/4 - 5 3/4
Clutch (MZZ)
After adjusting, check to make sure that the
amount of play in the clutch pedal is within
specifications.
5E-41
Air leakage
After increasing air pressure to greater than 0.59MPa
(6 kg/cm2 / 85 psi), stop the engine, and inspect each
of the areas of the clutch booster for air leakage.
2
1
MFW45ESH009301
Legend
1. Lock nut
2. Push rod
Inspection
Inspection of push rod, clevis and clevis pin
Inspect the clutch booster for abnormal sounds
around clevis or push rod. And inspect the clevis,
clevis pin and push rod for unusual wear, cracks
and bentness. If an abnormality is detected,
replacement of those is needed.
MFW45ESH009401
Oil leakage
Depress the clutch pedal and inspect the pipe
connections and clutch booster body for oil leakages.
Depress the clutch pedal to a certain extent, hold it in
this position, and feel if there are any changes in the
pedal force over time.
If there are no abnormalities, the piston cup gasket and
oil seals can be judged to be working properly.
On vehicle test
Install the clutch booster to the vehicle and after
removing air from pipes and adjusting the length of
the push rod, perform the following inspections
and tests.
- Air leakage
- Oil leakage
- Operational test
MFW45ESH009501
5E-42
Clutch (MZZ)
Operational test
Depress the clutch pedal repeatedly and judge whether
there is delay in operation based on the movement of
the push rod and the sounds coming from the exhaust
cover.
MFW45ESH009601
Clutch (MZZ)
5E-43
Clutch size
14 inch
Engine type
4HK1-TCC
Power piston diameter stroke
(mm (in))
70 (2.76) 35.8 (1.41)
Hydraulic piston diameter
(mm (in))
19.05 (0.7500)
Push rod diameter
(mm (in))
8 (0.31)
Relay piston section diameter
(mm (in))
16 (0.6299) 3.6 (0.142)
Valve piston section diameter
(mm (in))
23.5 (0.925)
mm (in)
Relay piston diameter

Gap between
relay piston and
cylinder body
Hydraulic
diameter
Relay piston section

(16 (0.6299))
Valve piston
section
(23.5
(0.925))
piston Power piston 70 (2.76)
Nominal
dimension
Assembly
standard
Limit for use
Remarks
16.00
(0.6299)
15.93
(0.6271)
0.04 - 0.09
0.11 (0.0043)
(0.0016 - 0.0035)
0.1 - 0.25
(0.0040 - 0.0098)
0.3 (0.1181)
19.05
(0.7500)
19.01
(0.7484)
0.01 - 0.06
0.08 (0.0031)
(0.0004 - 0.0023)
Gap between hydraulic piston and hydraulic

cylinder
Power piston
return spring
86.8 (3.417)
62.8
(6.4 / 14.1)
Compressed
length 59.9
(2.358)
28.2 (1.110)
9.8 (1.0 / 2.2)
Compressed
length 13.1
(0.516)
22.1 (0.870)
2.3 (0.23 /
8.1)
Compressed
length 13
(0.512)
Relay valve
spring
Poppet valve
spring
Free length
Power piston
70 (2.76)
Installed
load
N (kg / lb)
Power piston
70 (2.76)
Free length
Power piston
70 (2.76)
Installed
load
N (kg / lb)
Power piston
70 (2.76)
Free length
Installed load N (kg / oz)
5E-44
Clutch (MZZ)
e
f
a
b
MFWB5ELF000401
Legend
(a)
(b)
(c)
(d)
25 Nm (2.5 kgm / 18 lbft)

(2 caulking positions)
25 Nm (2.5 kgm / 18 lbft)
17 Nm (1.7 kgm / 12 lbft)
(power piston diameter 70 (2.76))
42 Nm (4.3 kgm / 31 lbft)
(e)
(f)
(g)
(h)
17 Nm (1.7 kgm / 12 lbft)

10 Nm (1.0 kgm / 87 lbin)
25 Nm (2.5 kgm / 18 lbft)
5 Nm (0.5 kgm / 43 lbin)
Side Power Take-Off (MZZ)
Side Power Take-Off
(MZZ)
TABLE OF CONTENTS
Air Control Type PTO . . . . . . . . . . . . . . . . . . . . . 5G1-2
Description of Function and Operation . . . . . . 5G1-2
List of Failures. . . . . . . . . . . . . . . . . . . . . . . . . 5G1-3
Primary Specifications. . . . . . . . . . . . . . . . . . . 5G1-3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-7
List of Tightening Torques . . . . . . . . . . . . . . . 5G1-11
5G1-1
5G1-2
Air Control Type PTO

7
6
MFW75GLF000301
Legend
1. Air Cylinder
2. Shift Arm
3. Idle Gear Shaft
4. Output Shaft
5. Output Gear
6. Idle Gear
7. Shift Rod
5G1-3
List of Failures
PTO
Condition
Possible Cause
Abnormal noise from the PTO
Gear engagement failure in the PTO
Gear disengagement failure in the PTO
Oil leakage in the PTO
Correction
Wear and damage of the needle

bearing of the idle gear
Replace the bearing
Wear and damage of the bearing of the

output gear
Replace the bearing
Wear and damage on the O-ring of the

air cylinder
Replace the O-ring
Wear on the tip of the sleeve and gear
Replace the gear
Chips and tears in the return spring
Replace the return spring
Damage on the tip of the sleeve and

gear
Replace the gear
Abnormalities in the seal on the seal

cover installation surface
Repair the liquid gasket
Abnormalities in the seal on the air

cylinder installation surface
Repair the liquid gasket
Abnormalities in the oil seal for the

output shaft, or wear on the seal contact
surface of the output shaft
Replace the oil seal or the output shaft
Item
Allowable maximum output torque
Specification
245 Nm (25.0 kgm / 181 lbft) / 1000 r/min
Speed increasing ratio (revolution ratio against the engine)
0.773
Rotational direction (When seen from the rear side of PTO)
Right rotation (clockwise)
5G1-4
Components
9
8
7
11
5
4
13
10
12
23
22
3
21
20
19
1
16
18
17
25
15
14
26
24
25
25
Legend
1. Thrust Collar
2. Needle Bearing
3. Idle Gear
4. Shift Arm
5. Spring Pin
6. Collar
7. Return Spring
8. O-ring
9. Shift Rod
10. Air Cylinder
11. Connector
12. Idle Gear Shaft
13. Spring Pin
Disassembly
1. Remove the PTO ASM from the transmission
case.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
MFW75GLF000101
Front Cover
Front Bearing
Output Shaft
Key
Output Gear
Distance Collar
Rear Bearing
Oil Seal
Seal Cover
Nut
Shift Plug
Plug
Case
2. Remove the plug.

Use a flat-blade screwdriver, etc., to remove the
plug.

3. Remove the spring pin.
Bury the spring pin that fixes the idle gear shaft
into the shaft.
4. Remove the idle gear shaft.
Remove the idle gear shaft by tapping it with a
copper hammer.
Remove the spring pin.
5. Remove the idle gear.
6. Remove the thrust collar.
7. Remove the needle bearing.
Remove the needle bearing from the idle gear.
5G1-5
18. Remove the shift plug.
6
5
3
10
9
1
3
4
4
MFW75GSH009401
MFW75GSH005901
Legend
1. Thrust collar
2. Idle gear
3. Needle bearing
4. Plug
5. Spring pin
6. Idle gear shaft
Legend
1. Shift plug
2. Shift arm
3. Return spring
4. Spring pin
5. Shift rod
6. O-ring
7. Key
8. Nut
9. Air cylinder
10. Connector
19.
20.
21.
22.
Remove the front cover.

Remove the seal cover.
Remove the oil seal.
Remove the output shaft.
Remove the output shaft to the front side by
tapping it with a copper hammer.
8. Remove the key.

Remove the key from the output shaft.
9. Remove the nut.
10. Disconnect the connector.
11. Remove the air cylinder.
12. Remove the spring pin.
Remove the spring pin that is fixed to the shift
arm.
13. Remove the shift rod.
Remove the shift rod from the shift arm.
14. Remove the shift arm.
15. Remove the O-ring.
16. Remove the return spring.
17. Remove the collar.
MFW75GSH000101
23. Remove the output gear.

24. Remove the distance collar.
5G1-6
25. Remove the front bearing.

26. Remove the rear bearing.
Inspection
Clean each part.
If wear, damage, corrosion, or other abnormalities
are found on the disassembled parts, repair or
replace the defective parts.
Gear (idle gear and output gear)
Inspect whether there is any damage on the gear
tooth surface. Inspect the bearing's sliding surface
for damage.
Repair minor stepped wear and roughness on the
gear tooth surface with an oil stone or pencil
grinder. Make replacements if there is significant
wear.
MFW45CSH051801
Needle bearing
Inspect the race and the roller surface for
discoloration, wear, detachment, or scratches.
MFW45CSH051501
Bearing
Inspect each bearing for scratches, detachment, wear,
or abnormal sounds.
Inspect for scratching and peeling in the area near
the gap of the roller as well as throughout the
whole area of the race.
When inspecting for wear, check whether there is
any abnormal "looseness" between the roller and
the race.
When inspecting for abnormal noise and
smoothness of the rotation, turn the bearing by
hand and feel if there are any abnormalities.
MFW45CSH051601
Shift arm
Measure the thickness of the tip of the shift arm.
Thickness of the tip of the shift arm
Nominal Dimension = 7 (0.28)
Limit for use = 6 (0.24)
mm (in)
MFW45CSH051701
Output shaft
Inspect whether there is any wear or damages on
the contact surface of the oil seal for the output
shaft.
MFW75GSH008201
Reassembly
Clean each mounting surface.
Clean each part thoroughly.
Replace the oil seal, plug, shift plug, and key with
new ones.
Apply gear oil, BESCO L-2, BESCO L-3 grease or
equivalent to each sliding surface, as required
accordingly.
1. Install the output gear.
2. Install the distance collar.
3. Install the output shaft.
Mount the distance collar and output gear to the
case, align the spline, and then insert them
through the front side by tapping the shaft.
5G1-7
MFW75GSH000201
4. Install the front bearing.

5. Install the rear bearing.
Install the front and rear bearings to the output
shaft.
MFW75GSH000301
6. Install the oil seal.

Apply gear oil to the outer circumference of the
oil seal.
Orient the lip area towards the inside, and
insert until it reaches the same surface as the
surface of the seal cover while avoiding
distortion. Then, apply a thin layer of grease
(BESCO L-2 or L-3 grease or equivalent) to the
inside surface of the lip area.
5G1-8
MFW75GSH006101
Legend
1. Seal cover
2. Oil seal
11. Install the idle gear.

12. Install the shift arm.
7. Install the seal cover.

Apply ThreeBond 1215 or equivalent to the seal
cover and perform installation.
Tightening torque:
25 Nm(2.5 kgm / 18 lbft)
8. Install the front cover.

Apply ThreeBond 1215 or equivalent to the
front cover and then install it.
Apply LOCTITE 242 or equivalent to the
threaded area of the installation bolt and install.
Tightening torque:
MFW45CSH052401
NOTE:
Make sure the direction of the shift arm is correct.
13. Install the thrust collar.
Orient the shift arm mounting side to the seal
cover side, and then insert the idle gear and the
shift arm into the case. Then, mount the thin
thrust collar to the front side of the idle gear,
and the thick thrust collar to the rear side of the
idle gear. In this case, work can be easily
conducted by applying grease to the thrust
collar.
25 Nm(2.5 kgm / 18 lbft)
MFW75GSH000501
MFW75GSH000401
9. Install the key.

Mount the key to the output shaft.
10. Install the needle bearing.
Apply gear oil to the needle bearing, and
assemble it to the idle gear.
14. Install the idle gear shaft.

15. Install the spring pin.
Align the spring pin hole for the case with the
spring pin hole for the idle gear shaft, insert the
shaft and fix it by tapping the spring pin until it
reaches the same surface as the case.
MFW75GSH000601
Legend
1. Spring pin
2. Idle gear shaft
16.
17.
18.
19.
5G1-9
Install the collar.

Install the return spring.
Attach the O-ring to the shift rod.
Install the shift rod.
While inserting the shift rod, assemble the shift
arm.
MFW75GSH000801
21. Mount the plug.

Apply LOCTITE 962T or equivalent to the outer
circumference of the plug, and tap the plug until
it reaches the same surface as the case while
making sure that distortion does not occur.
22. Install the shift plug.
Apply LOCTITE 962T or equivalent to the
cover, and tap it while making sure that
distortion does not occur.
23. Install the air cylinder.
Apply ThreeBond 1215 or equivalent to the air
cylinder and perform installation.
inner circumference of the cylinder and install.
Tightening torque:
25 Nm(2.5 kgm / 18 lbft)
24. Install the connector.

Apply LOCTITE 242 or equivalent to the
tapered threaded section and install.
1
2
Tightening torque:
3
MFW75GSH000701
Legend
1. Return spring
2. Shift rod
3. O-ring
20. Install the spring pin.
Fix the shift arm by using the spring pin.
22 Nm(2.2 kgm / 16 lbft)
5G1-10

3
1
4
1
1
MFW75GSH000901
Legend
1. Plug
2. Air cylinder
3. Connector
4. Shift plug
25. Install the nut.
26. Install the PTO ASM to the transmission case.
Apply ThreeBond 1215 or equivalent to the
transmission case, and then install the PTO
ASM.
Tightening torque:
36 Nm(3.7 kgm / 27 lbft)
5G1-11
b
c
Legend
(a)
(b)
(c)
25 Nm(2.5 kgm / 18 lbft)

25 Nm(2.5 kgm / 18 lbft)
22 Nm(2.2 kgm / 16 lbft)
(d)
25 Nm(2.5 kgm / 18 lbft)
MFW85GLF000701
MEMO
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 1
Published: Feb., 2011

First Edition
All rights reserved.
WORKSHOP MANUAL
TRANSMISSION
(MZZ model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 2
2011MY
2011MY
WORKSHOP MANUALTRANSMISSION (MZZ model)
No.MGMZZ-WE-1101
WORKSHOP MANUAL
TRANSMISSION
(MZZ model)

@5 MZZ Transmission

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

@5 MZZ Transmission

Hochgeladen von

Copyright:

Verfügbare Formate

2011MY

WORKSHOP MANUALTRANSMISSION (MZZ model)

MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 1

BODY, CAB AND ACCESSORIES

MGMZZ-WE-1101_67385 2011.2.7 3:35 PM 2

Manual Transmission (MZZ)

Manual Transmission (MZZ)

Manual Transmission (MZZ)

Falling out of gears

Wear on the flywheel pilot bearing

Wear or damage on the bearing (main

Wear, scratches, or damage on the

Wear on the spline (main shaft and

Scorching on the gear or bearing thrust

Not enough backlash in the mating gear

Failure in clutch pedal play

Wear on the sliding section of the gear

Wear on the sliding section of the shift

Wear on the groove of the synchronizer

Replace the worn-out part

Wear on the thrust washer, collar, or

Replace the worn-out part

Wear on the synchronizer components

Wear on the detent ball, ball seat, and

Replace the detent ASM

Wear on the sliding section of the

Wear on the groove of the synchronizer

Replace the worn-out part

Wear on the thrust washer, collar, or

Replace the worn-out part

Wear or damage on the bearing

Wear on the spline (main shaft and

Loosening of the drain plug or the filler

Tighten the plugs and replenish oil

Breaking of the gasket

Wear or damage on the oil seal

Transmission oil inspection

4. Tighten the filler plug to the specified torque.

39 Nm (4.0 kgm / 29 lbft)

Manual Transmission (MZZ)

39 Nm (4.0 kgm / 29 lbft)

4. Remove the filler plug.

Oil capacity [Reference value]

Without side PTO

With side PTO

6. Tighten the filler plug to the specified torque.

39 Nm (4.0 kgm / 29 lbft)

1. Start the engine and warm up the transmission

Number of primary teeth

Without side PTO

4.4L(1.16 US gal./0.97 Imp gal.)

With side PTO

5.3L(1.40 US gal./1.17 Imp gal.)

Manual Transmission (MZZ)

Tool Number/ Description

Tool Number/ Description

Manual Transmission (MZZ)

Tool Number/ Description

Manual Transmission (MZZ)

Shift Lever ASM

Manual Transmission (MZZ)

5. Remove the E-ring (1), select lever (2), and spring

6. Remove nut (5), and then remove the shift lever