Part 1 of 2

INTERMEDIATE PLATE WITH GEAR ASSEMBLY, DETENT, SHIFT ARM, AND INTERLOCK PIN (MUA)





Disassembled View

Disassembly





1. Remove detent spring plate and gasket (1), detent spring (2) and detent ball (3). Use a magnetic hand to remove the detent balls from the intermediate plate.
2. Remove spring (4).





3. Remove rev-5th shift rod (5), and rev-5th shift arm and reverse inhibitor (6). Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8), 3rd-4th shift arm (9), and 1st-2nd shift arm.

- Hold a round bar against the shift rod end (10).





- Use a spring pin remover to remove the shift arm spring pins from the shift arms and the shift rods.





- Move the 3rd-4th shift rod forward.
- Remove the rev-5th, 1st-2nd and 3rd-4th shifter rods carefully. Interlock pins are located between the shifter rods in the intermediate plate.

4. Remove interlock pin (11) from intermediate plate and gear assembly (12).


Inspection And Repair
Make the necessary adjustments, and part replacements if excessive wear or damage is discovered during inspection.

Shift Arm Thickness
Use a micrometer to measure the shift arm thickness. If the measured value is less than the specified limit, the shift arm must be replaced.








Shift Arm Thickness

Detent Spring Free Length
- Use a vernier caliper to measure the detent spring free length. If the measured value is less than the specified limit, the detent spring must be replaced.








Detent Spring Free Length

Detent Spring Tension
- Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the detent spring must be replaced.








Detent Spring Tension


Reassembly
1. Install 1st-2nd shift arm (10) and 3rd-4th shift arm (9) to intermediate plate and gear assembly (12).
2. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).
- Install the interlock pin (11) to the shift rod.
- Install the shift rod together with the interlock pin to the intermediate plate. Do not allow the interlock pin to fall from the shift rod.
- Hold a round bar against the shift rod end lower face to protect it against damage.





- Install a new spring pin. Never reinstall the used spring pin.
3. Install rev-5th shift arm and reverse inhibitor (6) and rev-5th shift rod (5).
- Apply oil to the reverse inhibitor inner surface.
- Install the interlock pin (11) to the shift rod.
- Install the shift rod together with the interlock pin to the intermediate plate. Do not allow the interlock pin to fall from the shift rod.
- Hold a round bar against the shift rod end lower face to protect it against damage.
- Install a new spring pin. Never reinstall the used spring pin.
4. Install spring (4).
5. Put detent balls (3) in the intermediate plate holes.
- Apply oil to the detent balls,





6. Install detent springs (2) and detent spring plate and gasket (1).
- Install a new gasket and the detent spring plate.
- Tighten the detent spring plate bolts to the specified torque.

Torque: 20 Nm (14 ft. lbs.)


REVERSE GEAR AND 5TH GEAR (MUA)





Disassembled View

Disassembly
1. Use a pair of snap ring pliers to remove the bearing snap ring (1). (4X2)





2. Set the bearing remover J-37217 and puller J-37487 to the bearing and the mainshaft end to remove ball bearing (2). (4X2)
3. Remove bearing snap ring (3), speedometer drive gear (4), clip (5), retainer snap ring (6) and retainer (7). (4X2)





4. Set the retaining ring remover J-37222 and puller J-37487 to the retainer (7) and the mainshaft end. (4X4)
5. Remove the retainer (7) together with the bearing (2) and the oil seal collar (1). (4X4) The universal puller may be used in place of the retaining ring remover.
6. Remove thrust plate (8) and thrust washer and lock bail (9).





7. Use a pair of snap ring pliers to remove reverse idler gear snap ring (10).





8. Remove the reverse idler gear assembly (11) from the intermediate plate (30).
9. Remove idle shaft pin (12), thrust washer (13), reverse idler gear (14), and reverse idler shaft (15).
10. Use a pair of snap ring pliers to remove the snap ring (16).





11. Attach the bearing remover to the counter gear shaft. Use the bearing remover to remove the ball bearing (17) and the counter 5th gear (18).
12. Remove counter reverse gear (19).





13. Remove 5th gear (20), 5th block ring (21), and needle bearing (2 piece type) (22).





14. Engage the 3rd-4th synchronizer with the 3rd gear. Engage the 1st-2nd synchronizer with the 1st gear. Attach the holding fixture J-37224 and base J-3289-20 to the mainshaft and the counter gear.





Use the mainshaft nut wrench J-37219 to remove the mainshaft nut (23).





15. Use pry bars between the reverse gear (26) and bearing plate (28) to remove the Rev-5th synchronizer assembly (24) together with reverse block ring (25) and reverse gear (26).
16. Remove needle bearing (27).





17. Use the torx bit wrench J-37225 (T45) to remove the bearing plate and screw(28) from the intermediate plate.





18. Use the snap ring pliers (2) to remove the mainshaft bearing snap ring (1) (29).
19. Hold the snap ring open with the pliers. Push the intermediate plate (30) toward the rear of the transmission to remove it. The bearing snap ring will come free.

Inspection And Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter Gear for inspection and repair.

Reassembly





1. Mesh the counter gear with the mainshaft assembly. Install the holding fixture J-37224 and base J-3289-20 to the mainshaft and the counter gear.
2. Place the holding fixture (with the mainshaft and the counter shaft) in a vise. Install the intermediate plate (30).
3. Install bearing snap ring (29).





4. Apply recommended thread locking agents (LOCTITE 242) or its equivalent to each of the bearing plate screw threads. Install bearing plate and screw(28). Tighten the screws to the specified torque by using torx bit wrench J-37225.

Torque: 15 Nm (11 Ft. lbs.)

5. Install needle bearing (27), reverse gear (26), and reverse block ring (25).
6. Assemble rev-5th synchronizer assembly (24) by performing the following steps.





1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the outer circumference.
2. Check that the inserts (3) fit snugly into the block ring insert grooves.





3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the reverse gear side.





7. Mesh the 1st-2nd and 3rd-4th synchronizers with both the 1st and 3rd gears (double engagement).
This will prevent the mainshaft from turning.





8. Install the new mainshaft hub nut. Use the mainshaft nut wrench J-37219 to tighten the mainshaft nut (23) to the specified torque.

Torque: 137 Nm (101 Ft. lbs.)





9. Use a punch to stake the mainshaft nut.
10. Install needle bearing (22), 5th block ring (21), and 5th gear (20).





11. Apply engine oil to the counter reverse gear (19) and the reverse gear (26). Install the counter reverse gear (19) to the counter shaft. The reverse gear projection must be facing the intermediate plate.





12. Install the counter 5th gear (18) to the transmission.





13. Install ball bearing (17) and bearing snap ring by performing the following steps:
Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.





- There are six snap ring sizes available. The snap rings are color-coded to indicate their thickness.

- Ball Bearing and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 inch)





Snap Ring Availability

- Use a pair of snap ring pliers to install the snap ring (16) to the counter gear shaft. The snap ring must be fully inserted into the counter gear shaft snap ring groove.

14. Assemble reverse idler shaft (15), reverse idler gear (14), thrust washer (13), and idle shaft pin (12) into reverse idler gear assembly (11).





15. Select reverse idler gear snap ring (10) which will provide the minimum clearance between the intermediate plate (30) and the snap ring (10). There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness.
- Intermediate Plate and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 inch)





Snap Ring Availability





- Use a pair of snap ring pliers to install the snap ring to the reverse idler shaft. The snap ring must be fully inserted into the reverse idler shaft snap ring groove.
16. Install thrust washer and lock ball (9) by performing the following steps:
- Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.
- 5th Gear and Thrust Washer Clearance

Standard: 0.10 - 0.25 mm (0.004 - 0.010 inch)





- Measure clearance "A" as shown in the figure.
- Select appropriate thrust washer from chart.
- There are four thrust washer sizes available.
- The thrust washers are color coded to indicate their thickness.








Thrust Washer Availability
- Apply grease to the thrust washer and the lock ball.
- Install the thrust washer and the lock ball.
17. Install thrust plate (8) and retainer (7).
18. Install retaining snap ring (6), clip (5), speedometer drive gear (4), and bearing snap ring (3). (4X2)





19. Use the installer J-37223 to install the ball bearing (2) to the mainshaft. (4X2)
20. Install bearing snap ring (1). (4X2)





21. Apply engine oil to the bearing inner and outer circumference. (4X4) Use the installer J-37223 to install the ball bearing (2) to the mainshaft in proper direction. (4X4)
22. Install oil seal collar (1). (4X4)