Transmission disassembly (MVL)

1. Component views

Transmission (RZ4E, 2WD models)

Part name

  1. Shift rod and shift fork
  2. Input shaft
  3. Main shaft
  4. Counter shaft
  5. Backup light switch
  6. Detent plug
  7. Filler plug
  8. Drain plug
  9. Interlock plate
  10. Gasket
  11. Control box
  12. Harness bracket
  13. Bolt
  14. Harness bracket
  15. Neutral switch
  16. Bolt
  17. Speedometer driven gear (Models without ABS)
  18. Rear case
  19. Magnet
  20. Clutch housing
  21. Boot
  22. Counter shaft front bearing outer snap ring
  23. Input shaft front bearing outer snap ring
  24. Release bearing
  25. Shift fork
  26. Shift fork support
  27. Front cover
  28. Front oil seal
  29. Bolt

Tightening torque

5: 39 N・m { 4.0 kgf・m / 29 lb・ft }

6: 30 N・m { 3.1 kgf・m / 22 lb・ft }

7: 39 N・m { 4.0 kgf・m / 29 lb・ft }

8: 39 N・m { 4.0 kgf・m / 29 lb・ft }

13: 19 N・m { 1.9 kgf・m / 14 lb・ft }

15: 39 N・m { 4.0 kgf・m / 29 lb・ft }

16: 23 N・m { 2.3 kgf・m / 17 lb・ft }

26: 39.2 N・m { 4.0 kgf・m / 29 lb・ft }

29: 19 N・m { 1.9 kgf・m / 14 lb・ft }

Transmission (RZ4E, 4WD models)

Part name

  1. Shift rod and shift fork
  2. Input shaft
  3. Main shaft
  4. Counter shaft
  5. Backup light switch
  6. Detent plug
  7. Filler plug
  8. Drain plug
  9. Interlock plate
  10. Gasket
  11. Control box
  12. Harness bracket
  13. Bolt
  14. Harness bracket
  15. Neutral switch
  16. Bolt
  17. Rear case
  18. Magnet
  19. Clutch housing
  20. Boot
  21. Counter shaft front bearing outer snap ring
  22. Input shaft front bearing outer snap ring
  23. Release bearing
  24. Shift fork
  25. Shift fork support
  26. Front cover
  27. Front oil seal
  28. Bolt

Tightening torque

5: 39 N・m { 4.0 kgf・m / 29 lb・ft }

6: 30 N・m { 3.1 kgf・m / 22 lb・ft }

7: 39 N・m { 4.0 kgf・m / 29 lb・ft }

8: 39 N・m { 4.0 kgf・m / 29 lb・ft }

13: 19 N・m { 1.9 kgf・m / 14 lb・ft }

15: 39 N・m { 4.0 kgf・m / 29 lb・ft }

16: 23 N・m { 2.3 kgf・m / 17 lb・ft }

25: 39.2 N・m { 4.0 kgf・m / 29 lb・ft }

28: 19 N・m { 1.9 kgf・m / 14 lb・ft }

Transmission (4JJ3, 2WD models)

Part name

  1. Shift rod and shift fork
  2. Input shaft
  3. Main shaft
  4. Counter shaft
  5. Backup light switch
  6. Detent plug
  7. Filler plug
  8. Drain plug
  9. Interlock plate
  10. Gasket
  11. Control box
  12. Harness bracket
  13. Bolt
  14. Harness bracket
  15. Neutral switch
  16. Bolt
  17. Speedometer driven gear (Models without ABS)
  18. Rear case
  19. Magnet
  20. Clutch housing
  21. Boot
  22. Counter shaft front bearing outer snap ring
  23. Input shaft front bearing outer snap ring
  24. Release bearing
  25. Shift fork
  26. Shift fork support
  27. Front cover
  28. Front oil seal
  29. Bolt

Tightening torque

5: 39 N・m { 4.0 kgf・m / 29 lb・ft }

6: 30 N・m { 3.1 kgf・m / 22 lb・ft }

7: 39 N・m { 4.0 kgf・m / 29 lb・ft }

8: 39 N・m { 4.0 kgf・m / 29 lb・ft }

13: 19 N・m { 1.9 kgf・m / 14 lb・ft }

15: 39 N・m { 4.0 kgf・m / 29 lb・ft }

16: 23 N・m { 2.3 kgf・m / 17 lb・ft }

26: 39.2 N・m { 4.0 kgf・m / 29 lb・ft }

29: 19 N・m { 1.9 kgf・m / 14 lb・ft }

Transmission (4JJ3, 4WD models)

Part name

  1. Shift rod and shift fork
  2. Input shaft
  3. Main shaft
  4. Counter shaft
  5. Backup light switch
  6. Detent plug
  7. Filler plug
  8. Drain plug
  9. Interlock plate
  10. Gasket
  11. Control box
  12. Harness bracket
  13. Bolt
  14. Harness bracket
  15. Neutral switch
  16. Bolt
  17. Rear case
  18. Magnet
  19. Clutch housing
  20. Boot
  21. Counter shaft front bearing outer snap ring
  22. Input shaft front bearing outer snap ring
  23. Release bearing
  24. Shift fork
  25. Shift fork support
  26. Front cover
  27. Front oil seal
  28. Bolt

Tightening torque

5: 39 N・m { 4.0 kgf・m / 29 lb・ft }

6: 30 N・m { 3.1 kgf・m / 22 lb・ft }

7: 39 N・m { 4.0 kgf・m / 29 lb・ft }

8: 39 N・m { 4.0 kgf・m / 29 lb・ft }

13: 19 N・m { 1.9 kgf・m / 14 lb・ft }

15: 39 N・m { 4.0 kgf・m / 29 lb・ft }

16: 23 N・m { 2.3 kgf・m / 17 lb・ft }

25: 39.2 N・m { 4.0 kgf・m / 29 lb・ft }

28: 19 N・m { 1.9 kgf・m / 14 lb・ft }

2. Transmission cleaning

1) Clean the external portion of the unit with solvent.

3. Shift fork removal

1) Remove the release bearing and spring as a set from the clutch housing.

2) Remove the shift fork and boot from the clutch housing.

4. Control box removal

1) Remove the control box and gasket from the rear case.

2) Remove the interlock plate from the rear case.

3) Remove the neutral switch from the control box.

5. Front cover removal

1) Remove the front cover from the transmission case.

2) Remove the front oil seal from the front cover.

3) Remove the counter front bearing snap ring from the counter shaft using snap ring pliers.

4) Remove the input shaft bearing snap ring from the input shaft using snap ring pliers.

Legend

  1. Front cover
  2. Front oil seal
  3. Input shaft bearing snap ring
  4. Counter front bearing snap ring

6. Speedometer driven gear removal

1. 2WD models (Models without ABS)

1) Remove the speedometer driven gear and speedometer bushing as a set from the rear case.

7. Backup light switch removal

1) Remove the backup light switch and gasket from the rear case.

8. Detent removal

1) Remove the detent from the rear case.

9. Rear case removal

1) Place with the transmission clutch housing side on the bottom.

2) Open the main shaft rear bearing snap ring from the rear case control box opening section.

Note

  • Widen the snap ring inside edge.

Legend

  1. Snap ring inside edge
  2. Snap ring

3) Remove the rear case from the clutch housing.

10. Main shaft removal

1) Remove the following parts as a set from the clutch housing.

  • Input shaft
  • Main shaft
  • Counter shaft
  • Each shift arm and shift rod

11. Shift rod disassembly

1) Remove the spring pin from the 3rd - 4th shift block.

2) Remove the 3rd - 4th shift block from the 1st - 2nd and 3rd - 4th shift rod.

3) Remove the 1st - 2nd shift arm from the 1st - 2nd and 3rd - 4th shift rod.

Legend

  1. 3rd - 4th shift arm
  2. 1st - 2nd and 3rd - 4th shift rod
  3. Spring pin
  4. 3rd - 4th shift block
  5. 1st - 2nd shift arm

4) Remove the spring pin from the 3rd - 4th shift arm.

5) Remove the 3rd - 4th shift arm from the 1st - 2nd and 3rd - 4th shift rod.

Legend

  1. 1st - 2nd and 3rd - 4th shift rod
  2. 3rd - 4th shift arm
  3. Spring pin

6) Remove the reverse shift arm from the reverse and 5th - 6th shift rod.

7) Remove the spring pin from the 5th - 6th shift block.

8) Remove the 5th - 6th shift block from the reverse and 5th - 6th shift rod.

9) Remove the spring pin from the 5th - 6th shift arm.

10) Remove the 5th - 6th shift arm from the reverse and 5th - 6th shift rod.

Legend

  1. Spring pin
  2. Spring pin
  3. 5th - 6th shift block
  4. 5th - 6th shift arm
  5. Reverse and 5th - 6th shift rod
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