M.taller Transmisión (MZW Model) 2009MY F&G Series PDF

2009MY
2009MY
WORKSHOP MANUAL
WORKSHOP MANUAL TRANSMISSION (MZW model)

TRANSMISSION
(MZW model)
No.MGMZW-WE-0991
MGMZW-WE-0991_62502前書 2009.9.14 1:19 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
4G Trailer Brake
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G Power Take-Off (PTO)
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME AND FRAME ACCESSORIES 11A Frame
MGMZW-WE-0991_62502前書 2009.9.14 1:19 PM ページ 2
MGMZW-WE-0991.book 1 ページ２００９年９月１８日　金曜日　午後３時３２分
Manual Transmission (MZW) 5C-1
TRANSMISSION/TRANSAXLE
Manual Transmission
(MZW)
TABLE OF CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
Description of Function and Operation . . . . . . . 5C-2 Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-56
Functional Inspection . . . . . . . . . . . . . . . . . . . . 5C-5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-56
Primary Specifications. . . . . . . . . . . . . . . . . . . . 5C-6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-58
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-58
Shift Lever ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9 List of Tightening Torques . . . . . . . . . . . . . . . . 5C-60
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10
Gear Control Cable . . . . . . . . . . . . . . . . . . . . . . 5C-12
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . 5C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Backup Light Switch. . . . . . . . . . . . . . . . . . . . . . 5C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-18
Transmission ASM . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-20
MZW Transmission . . . . . . . . . . . . . . . . . . . . . . 5C-21
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-21
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-27
List of Tightening Torques . . . . . . . . . . . . . . . . 5C-38
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-39
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-39
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-40
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-41
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-43
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-44
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-48
Gear Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-52
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-53
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-54
Relay Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-55
5C-2 Manual Transmission (MZW)
General Description
Description of Function and Operation
Outline view
1 2
MFW95CLF000101
Legend
1. MZW Transmission 2. Control Box

Cross Section
MFW75BLF000201
MZW type transmission Gear shaft (oil pump)

Output reduction • The input shaft is a gear shaft that has a built-in oil
• By adopting the output reduction mechanism, pump. Oil is send out from the oil pump to each
significant reduction in weight and noise is gear shaft (reverse idle shaft, input shaft, counter
implemented to the existing transmission with shaft, and output shaft).
similar permitted torque level. Bearing
Gear • A roller bearing is used for the bearing of the input
• The MZW type transmission adopts the shaft. A taper roller bearing is used for the
synchromesh type for gears excluding the reverse bearings at the front and middle sections of the
and the 1st gear. Helical gears are used for all counter shaft and a roller bearing is used at its
gears to reduce noise. The synchromesh back section.
mechanism adopts the type that balls and springs Needle roller bearings are used for the bearings at
are used instead of keys. In the mechanism, 3 corn the rear end section of the input shaft, 1st gear,
type is used for 2nd and 3rd gears to reduce the 2nd gear, 3rd gear, 4th gear, 6th gear and the
operating force, and the special brass block ring is reverse gear to ensure durability and silence.
used to improve the synchronizing performance.

Transmission case
• The clutch housing and the transmission case
have the cylindrical cases (4 pieces) made of light
aluminium die-cast and the side cover for installing
the power takeoff unit at the left side. The gear
control box is mounted at the top of the
transmission case.

Functional Inspection
Condition Possible Cause Correction

Abnormal noise Insufficient gear oil or bad gear oil Refill or replace
Wear on the flywheel pilot bearing Replace
Wear or damage of the bearing (input Replace
shaft, counter shaft, and output shaft)
Wear, scratches, or damage on the Replace
gear (input shaft, counter shaft, output
shaft, and reverse idle gear)
Wear on the spline (main shaft and Replace
synchronizer clutch hub)
Seize on the gear or bearing thrust Replace
Insufficient backlash in the mating gear Replace
Displacement of the transmission Adjust
Difficulty in shifting Insufficient gear oil or bad gear oil Refill or replace
Failure in clutch pedal play Adjust
Wear or insufficient grease on the shift Repair or replace, apply grease
lever sliding area
Shift block operation failure Repair or replace
Wear on the groove of the synchronizer Replace the worn-out part
sleeve or the shift arm
Wear on the thrust washer, collar or Replace the worn-out part
gear thrust surface (play in the input
shaft and counter shaft thrust)
Wear on the synchronizer components Replace
Falling out of gears Wear on the shift lever sliding area, Replace the worn-out part
excessive amount of play
Wear on the detent ball, ball seat, and Replace the detent ASM
spring
Wear on the sliding section of the Replace
control box or shift rod
Wear on the groove of the synchronizer Replace the worn-out part
sleeve or the shift arm
Wear on the thrust washer, collar or Replace the worn-out part
gear thrust surface (play in the input
shaft and counter shaft thrust)
Wear or damage on the bearing Replace
Wear on the spline (input shaft and Replace
synchronizer hub)
Weakening or damage to the Replace
synchronizer spring
Oil leakage Excessive amount of oil Adjust to the proper amount
Looseness of the drain plug or the filler Tighten the plugs and refill oil
plug
Gasket damage or breakage Replace
Wear or damage on the oil seal Replace

Transmission oil inspection Replacement of the transmission oil
1. Remove the filler plug. 1. Start the engine and warm up the transmission
2. Inspect whether the oil level is lower than the body sufficiently.
bottom edge of the hole, through the filler plug hole 2. Stop the engine, remove the drain plug and the
as shown in the diagram. filler plug, and then drain the oil.
3. Refill the oil if the oil level is below the specified
level. CAUTION:
Oil used Be careful not to burn while engine is hot.
• GL-5 BESCO GEAR OIL SH 80W-90 or 3. Tighten the drain plug.
equivalent
4. Tighten the filler plug at the specified torque. Tightening torque: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
4. From the filler plug hole, fill oil up to the lower edge
Tightening torque: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
of the filler plug hole.
Oil used
• GL-5 BESCO GEAR OIL SH 80W-90 or
equivalent
Oil capacity [Reference value] L (US gal. / lmp gal.)

1
without side PTO 5.3 (1.40 / 1.17)
with side PTO 6.0 (1.59 / 1.32)
5. Tighten the filler plug at the specified torque.

NOTE:
After conducting an transmission fluid change,
2 instrument panel (IP) cluster operation must be
performed to reset the maintenance time data. Refer to
MFW75CSH000101 "Instrument Panel (IP) Cluster System" in Section 9E
Legend Instrumentation/Driver Info.
1. Filler plug
2. Drain plug
Primary Specifications
Model MZW6P
Number of primary teeth 43 / 22
Gear ratio 1st 13 / 44 6.615
2nd 21 / 44 4.095
3rd 29 / 35 2.358
4th 37 / 29 1.531
5th Direct coupling 1.000
6th 46 / 17 0.722
Rev 13 / 27 / 44 6.615
Speedometer gear ratio 15 / 5
Oil capacity [Reference value] without side PTO 5.3 (1.40 / 1.17)
L (US gal. / lmp gal.)
with side PTO 6.0 (1.59 / 1.32)
Oil type API GL-5 BESCO GEAR OIL SH 80W-90 or equivalent

Special Tool
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2245-0
5-8840-0007-0
Control box oil seal
Grip
installer
5884022450
5-8840-0013-0 5-8840-2345-0
Bearing puller Installer
5884023450
5-8840-0014-0 5-8840-2757-0
Bearing remover leg Bearing remover
5884000140 5884027570
5-8840-0194-0 5-8840-2781-0
Shim selector Oil seal installer
5884001940 5884027810
5-8840-2184-0 5-8840-2794-0
Bearing installer Shim selector adapter kit
5884021840 5884027940
5-8840-2244-0 5-8840-2802-0
Bearing installer Push puller
5884022440 5884028020
Illustration Tool Number/ Description Illustration Tool Number/ Description
9-8521-0181-0
5-8840-2863-0
Speedometer gear
Driver tool set
remover
5884028630 9852101810
5-8840-2871-0 9-8522-0033-0
Oil seal installer Gear installer
5884028710 9852200330
5-8840-2873-0
Gauge pin
5884028730
5-8840-2874-0
Bearing installer
5884028740
5-8840-2875-0
Switch wrench
5884028750
9-8521-0056-0
Puller
9852100560
Shift Lever ASM

Components
8
7
6
5 3
4
2
9
10
11 13
12
14
17
15
18
16
MFW75CMF000201
Legend
1. Shift Lever Knob 11. Ball Seat
2. Gear Control Cover 12. Rubber Seat (except RHD Standard Cab with
3. Shift Lever ASM power assist)
4. Ball 13. Spring
5. Select Lever 14. Distance Piece
6. E-ring 15. Cushion Rubber
7. Spring Pin (RHD only) 16. Bracket ASM
8. Ring (RHD only) 17. Select Cable
9. Shift Lever 18. Shift Cable
10. Cover Plate
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.

5. Remove the E-ring (1), select lever (2), and spring 7. Pull out the spring pin (RHD only) (1) from the shift
(3), and remove the ball (4) from the select lever lever (3), and remove the ring (RHD only) (2).
(2).
2
1
4
3
2
1
MFW75CSH001601
MFW75CSH001701
8. Inspect the following parts.
6. Remove nut (5), and then remove the shift lever • Clean each part.
(1), the cover plate (2), the ball seat (3), and the
• If wear, damage, or other abnormalities are
rubber seat (except RHD Standard Cab with power
found in the disassembled parts, repair or
assist) (4) from the bracket ASM.
replace the defective parts.
• Inspect the ball seat and rubber seat for wear or
damage.
1
2 Reassembly
3
4 • 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).
1
5
MFW75CSH001501
MFW75CSH001601

2. Assemble the cover plate (2), the ball seat (3), and • Install the bushing (1) so that it faces the select
the rubber seat (4) (except RHD Standard Cab lever side.
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: 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
2
3
4
1
MFW75CSH005501
5 8. Assemble the shift and the outer cable of the

select cable to the bracket ASM and install with the
clip.
MFW75CSH001501 NOTE:
3. Assemble the ball (4) to the select lever (2). Check to see that there are no cracks or misalignments
caused by excessive tapping of the clip.
4. Assemble the spring (3) and the select lever (2) to
the shift lever ASM, and then fix them with the E- 9. Install the boot and cover.
ring (1).
10. Install the shift lever knob.
4
3
2
1
MFW75CSH001701
5. Mount the shift lever ASM to the cab.

6. Connect the shift cable to the shift lever.
7. Connect the select cable to the select lever.
Gear Control Cable

Components Transmission side (6H engine)
Cab side
2
2
1
MFW45DSH001201
MFW75CSH001201 Legend
1. Shift cable
Legend
2. Select cable
1. Select cable
2. Shift cable
Transmission side (4H engine) Installation

1. Adjust the length of the select cable (cab side) to
the specified value.
• Installation length of the select cable: 210 mm
(8.27 in)
1 2
MFW75CSH005601
Legend
1. Select cable
2. Shift cable
MFW75CSH001301
2. Install the select cable (cab side).

• Install the bushing (1) so that it faces the select
lever 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 • Loosen the lock nut on the ball joint, turn the
misalignments caused by excessive tapping of the ball joint and after adjusting the cable length,
clip. tighten each nut at the specified torque.
Tightening torque
Ball joint lock nut: 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
Ball joint tightening nut (M8):
22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
MFW75CSH005501
1 4
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) MFW75CSH001101
Legend
NOTE:
1. Lock nut
• Do not hold the guide pipe section of the control 2. Tightening nut
cable, when you install or remove the control cable, 3. To center of joint
as doing so could break the guide pipe. 4. Cab floor
• Check to see that there are no cracks or
misalignments caused by excessive tapping of the 5. Adjust the length of the select cable (transmission
clip. 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 select cable

Engine type Length
with without
power power
assist assist
295 mm 295 mm
4H Engine
(11.61 in) (11.61 in)
6H Engine 320 mm 320 mm
(Day cab) (12.60 in) (12.60 in)
MFW75CSH001401
6H Engine (Full cab) 350 mm 320 mm
4. Install the shift cable (cab side). (Cross member mounting) (13.78 in) (12.60 in)
(Side frame mounting⋅FVR) (12.60 in) (12.60 in)

4H Engine Installed length of the shift cable
Engine type Length
with without
power power
assist assist
1 230 mm 260 mm
4H Engine
(9.06 in) (10.24 in)
6H Engine 200 mm 225 mm
2
(Day cab) (7.87 in) (8.86 in)
(Cross member mounting) (9.60 in) (8.86 in)
(Side frame mounting⋅FVR) (7.87 in) (8.86 in)
4H Engine
MFW95CSH000401
6H Engine
1
1
2
2
MFW95CSH000601
6H Engine
MFW95CSH000501
6. Install the select cable (transmission 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.
1
Tightening torque
Ball joint lock nut : 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
Ball joint tightening nut (M8) :
22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
7. Adjust the length of the shift cable (transmission
side) to the specified value.
NOTE: 2
• 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 MFW95CSH000701
nut (2) to correct the twist. 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 N⋅m (1.3 kg⋅m / 113 lb⋅in)
Ball joint tightening nut (M8):
22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
Vehicle Speed Sensor

Removal
1. Remove the clip (3) and the protector (2).
2. Disconnect the harness connector (1).
2
3
MFW75CSH006801
3. Remove the vehicle speed sensor.
LNW75ASH000701
Installation
1. Install the vehicle speed sensor.
2. Connect the harness connector and fix it to the
protector with the clip.
Neutral Switch
Removal
1. Disconnect the harness connector.
2. Remove the neutral switch.
6H Engine
0.93mm
(0.04in)
LNW47BSH000201
Installation
MFW75CSH000301 1. Install the neutral switch.
4H Engine • Remove any old sealing agent, apply
ThreeBond 1141 or equivalent to the switch
screw in the area shown on the drawing, and
install it.
1
MFW75CSH006701
Inspection
• Replace the harness, connector, and seal if they
are damaged. MFW75BSH002001
• The switch is judged to be normal if there is Legend

continuity between both ends of the switch when in 1. Sealing agent coating area (within the half length
this state, and no continuity between both ends of of thread)
the switch when the ball is pressed.
2. Connect the harness connector.
Operation stroke of the switch
= 0.93 mm (0.04 in)
Backup Light Switch

Removal Installation
1. Disconnect the harness connector. 1. Install the backup light switch using the switch
2. Remove the backup light switch. wrench: 5-8840-2875-0.
• Remove the backup light switch using the • Remove any old sealing agent, apply LOCTITE
switch wrench: 5-8840-2875-0 (1). 242 or equivalent to the switch screw in the
area shown on the drawing, and install it.
MFW95CSH001301
Inspection MFW75BSH002001
• Replace the harness, connector, and seal if they Legend

are damaged. 1. Sealing agent coating area (within the half length
• The switch is judged to be normal if there is of thread)
continuity between both ends of the switch when in
this state, and no continuity between both ends of 2. Connect the harness connector.
the switch when the ball is pressed.
Operation stroke of the switch

= 0.93 mm (0.04 in)
0.93mm
(0.04in)
LNW47BSH000201
Transmission ASM
Removal 7. Remove the exhaust pipe bracket.
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 (-).
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.

MFW75BSH000601
1. Remove the filler plug and O-ring from the
transmission. 8. Remove the starter motor ASM. (4H engine)
2. Remove the drain plug and O-ring from the 9. Remove the power assist air hose.
transmission. • Disconnect the power assist air hose.
• Drain the transmission oil. When draining the 10. Remove the clutch booster ASM.
oil, check the amount of oil, and check whether • Remove the return spring.
there are any foreign materials such as metal
• Remove the spring hanger in the clutch lever
chips.
area, and disconnect the push rod from the
3. Remove the propeller shaft ASM. clutch lever.
• Place an alignment mark, and remove the • Remove the clutch booster ASM from the
propeller shaft ASM. transmission and fix it to the frame.
• Remove the propeller shaft guard, and tie the 11. Disconnect the select cable and the shift cable.
propeller shaft to the chassis side using a
• Separate the select cable from the select relay
lashing belt, etc.
lever.
4. Disconnect the inner cable of the parking brake
• Separate the shift cable from the power assist.
from the lever and separate the outer cable from
the bracket. (with parking brake) • Remove the bracket of the select and shift
cables from the transmission.
5. Remove the PTO propeller shaft ASM and air
hose. (with side PTO) 12. Remove the rear engine mounting from the cross
member. (4H engine)
• Place an alignment mark, and remove the PTO
propeller shaft ASM. 13. Remove engine - transmission installation bolts.
• Disconnect the PTO air hose. • Remove brackets and cables characteristic to
vehicle models.
6. Disconnect the frame harness connector from the
transmission harness connector, and remove the • Support transmission with a transmission jack.
frame harness clip from the transmission harness • Remove engine - transmission bolts (for 6H
bracket. engine: 12, for 4H engine: 10).
14. Remove the transmission ASM.
• Remove the transmission ASM from the engine
using a transmission jack.

Installation • Install the air hose to be connected to the
power assist using 2 wrenches.
1. Mount the transmission ASM.
• Apply grease (variant S or equivalent) to the top Tightening torque: 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
gear shaft spline.
8. Install the starter motor ASM. (4H engine)
• Slowly operate the transmission jack to lift the
• Connect the starter motor harness and ground.
transmission to make it closer to the engine.
9. Install the frame harness clip to the transmission
2. Tighten the engine - transmission installation bolt
harness bracket, and connect the frame harness
at its specified torque.
connector to the transmission harness connector.
Tightening torque: 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) 10. Connect PTO propeller shaft ASM and air hose.
(with side PTO)
• The exhaust pipe bracket shall also be
tightened. 11. Mount the cable bracket and the joint section of the
parking brake. (with parking brake)
Tightening torque 12. Mount the propeller shaft ASM.
Exhaust pipe bracket
• Mount the propeller shaft guard.
(Iron sheet):44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
13. Install transmission drain plug and O-ring.
(Casting):58 N⋅m (5.9 kg⋅m / 43 lb⋅ft)
14. Fill gear oil from the filler hole, and then install the
filler plug.
Tightening torque: 39 N⋅m(4.0 kg⋅m / 29 lb⋅ft)
15. Connect the battery cable (-).
MFW75BSH000601
3. Install the rear engine mounting to the cross

member. (4H engine)
4. Connect the select cable to the select relay lever.
5. Install the shift cable to the power assist.
Tightening torque: 22 N⋅m(2.2 kg⋅m / 16 lb⋅ft)
6. Install the clutch booster ASM.
• Install the clutch booster ASM bracket to the
transmission case.
• Connect the push rod to the clutch lever.
• Install the return spring.
7. Install the power assist air hose.
MZW Transmission
Components
8
1 5
9
4
2
7
3
6
35
34 10
33
36 32 11
37 31 12 13
38 14 15 17
39 16
40
41 18
26 19
20
43 28
29 27 25
42 44
45 30 24
46 23
22
47 55 21
48
49
50
51
52
53 54
56
57
58
61
59
60
MFW95CLF000401
Legend
1. Clutch Housing 18. 5th Block Ring
2. Front Oil Seal 19. Snap Ring
3. Gear Control (Lower) 20. 5th Dog Clutch
4. Relay Lever ASM 21. Counter End Nut
5. Gear Control (Upper) 22. Counter End Bearing
6. Front Case 23. Output Counter Gear
7. Interlock Plate 24. Collar
8. Engine Rear Mounting ASM RH (4H Engine) 25. 6th Counter Gear
9. Control Box 26. Magnet
10. Detent ASM 27. Backup Light Switch
11. Filler Plug 28. Packing
12. Drain Plug 29. PTO Cover
13. 6th Needle Bearing 30. Dummy Sensor Cap
14. 6th Gear 31. Shim
15. 6th Block Ring 32. Counter Middle Bearing Outer Race
16. 5th-6th Gear Clutch Hub ASM and Sleeve 33. Counter Front Bearing Outer Race
17. 5th-6th Gear Shift Arm 34. Oil Nozzle

35. Oil Port Cover 49. Output Shaft Rear Bearing Outer Race
36. Thrust Washer 50. Shim
37. Reverse Idle Gear 51. Rear Oil Seal
38. Reverse Idle Needle Bearing 52. Rear Cover
39. Pin 53. Set Bolt
40. Reverse Idle Shaft Bolt 54. Speed Meter Driven Gear
41. Reverse Idle Shaft 55. Parking Brake Cable Bracket
42. Rear Case 56. Parking Brake ASM
43. Output Shaft Front Bearing Outer Race 57. Flange ASM
44. Output Shaft Front Bearing Inner Race 58. Parking Brake Drum
45. Pilot Bearing 59. O-ring
46. Output Shaft 60. Main End Nut
47. Output Shaft Rear Bearing Inner Race 61. Engine Rear Mounting ASM LH (4H Engine)
48. Speed Meter Drive Gear
62
63
64
68
65 66
67
69
MFW85CLF000201
Legend
62. Input Shaft ASM 66. Bolt
63. Input Shaft 67. Screen ASM
64. Oil Pump ASM 68. Oil Pump Case
65. Hose 69. Counter Shaft ASM

Disassembly 11. Remove the parking brake cable bracket from the
transmission case.
CAUTION:
The transmission case and the clutch housing are 12. Loosen the set bolt and remove the speedometer
made of aluminum. Take sufficient care to prevent them bushing and the speedometer driven gear using
from becoming damaged. In particular, damage to the the speedometer gear remover: 9-8521-0181-0
rib may cause a reduction of case strength. Specially (1).
gentle handling of the rib part is necessary.
In addition, be careful not to injure yourself when
handling heavy objects such as cases and gears.
1. Disconnect the connector of sensor from the

transmission harness.
• Neutral switch
• Backup light switch
2. Remove the filler plug and O-ring.
3. Remove the drain plug and O-ring.
• 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.
4. Remove the release bearing, clutch shaft, and shift 1
fork.
• Refer to "Clutch ASM" in Section 5E Clutch MFW75CSH005201
(MZW). 13. Remove the bolts, and then remove the dummy
5. Remove the control box and the interlock plate. sensor cap.
6. Remove the detent ASM (4 positions). 14. Remove the PTO cover.
7. Remove the backup light switch using the switch 15. Remove the rear cover ASM.
wrench: 5-8840-2875-0 (1). • Install the transmission above the clutch
housing.
16. Remove the output shaft rear bearing outer race
and the shim from the rear cover ASM using a
brass rod.
MFW95CSH001301
8. Fully raise the crimped section (2 positions) of the

main end nut for the flange ASM, and then have
the gear double locked to remove the main end
nut. MFW75CSH001801
9. Remove the parking brake drum, flange ASM, and 17. Inspect the oil seal on the rear cover for wear or
O-ring. damage. If wear or damage is found, remove it
10. Remove the parking brake ASM. from the rear cover using a flat-blade screwdriver,
• Refer to "Parking Brake" in Section 4D, Parking etc.
Brake. 18. Remove the speedometer drive gear.
19. Remove the counter end nut.

• Have the gear double locked, and then raise 27. Remove the output shaft front bearing outer race
the crimped section of the nut and loosen it. from the rear case using the driver tool: 5-8840-
2863-0 (No. 90) (1).
NOTE:
The counter end nut is a left-hand thread.
1
20. Remove the counter end bearing using the bearing
puller: 5-8840-0013-0 (1) and the bearing remover
leg: 5-8840-0014-0 (2).
MFW75CSH002001
28. Remove the 5th dog clutch.

29. Remove the 5th block ring.
30. Remove the output counter gear.
31. Remove the collar.
MFW75CSH001901
32. Remove the 6th counter gear.
21. Remove the output shaft.
33. Remove the snap ring on the input shaft rear side.
22. Destroy the output shaft front bearing inner race
34. Pull out the pin from the 5th-6th gear shift arm, and
and remove it from the output shaft. (when
remove the shift arm together with the clutch hub
replacing)
ASM using a puller: 9-8521-0056-0 (1).
23. Destroy the output shaft rear bearing inner race
• For protection of the oil hole, remove it with a
and remove it from the output shaft. (when
copper plate, etc. placed on the shaft end.
replacing)
24. Remove the pilot bearing from the input shaft. NOTE:
25. Remove the rear case. Be cautious when removing, as the detent spring and
26. Remove the magnet. detent ball may suddenly jump out if the sleeve is
removed from the 5th-6th synchronizer ASM.
MFW75CSH000601
35. Disassemble the 5th-6th synchronizer ASM.


• Place an alignment mark beforehand when re- 40. Remove the counter middle bearing outer race and
using the clutch hub and sleeve. the shim from the front case using the driver tool:
• Wrap the detent ball with rag, etc. when 5-8840-2863-0 (No. 79).
disassembling, so as to avoid the detent ball 41. Remove the relay lever ASM.
from jumping out.
NOTE:
• Note that a different spring is used for Smoother and
manual transmission.
1
5
4
2
MFW75CSH003401
3
42. Remove the gear control (upper).
MFW45DSH005501
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
36. Remove the 6th gear and 6th block ring.

37. Remove the 6th needle bearing.
38. Remove the reverse idle shaft bolt.
MFW75CSH003301
MFW95CSH000901
39. Remove the front case.


43. Move the clamp (1) and disconnect the hose (2) of • Mount the bearing remover to the counter shaft,
the oil pump. fasten it with the counter end nut, install a wire
to them, and then lift them with a hoist.
1
2
MFW75CSH002201
MFW75CSH002301
44. Remove the bolt (3) from the oil pump case (1),
and then remove the hose and the screen ASM • Remove the input shaft ASM, counter shaft
(2). ASM, reverse idle shaft ASM and gear control
(lower) from the clutch housing at the same
time.
- Remove the reverse idle shaft ASM when
the input front bearing is removed from the
clutch housing.
1
NOTE:
Be cautious not to drop the gear control (lower) while
lifting it.
2
3
MFW75CSH000501
45. Remove the counter shaft ASM, input shaft ASM,

reverse idle shaft ASM, and gear control (lower)
from the clutch housing.
• Use the belt with the tightening function, such
as a lashing belt to firmly tighten the counter
shaft ASM and input shaft ASM by winding
them together at more than 2 positions to
prevent them from falling. MFW75CSH002401
46. Remove the pin, reverse idle gear, reverse idle

needle bearing (2 pieces) and thrust washer from
the reverse idle shaft.
47. Remove the oil port cover.
48. Remove the front oil seal.

49. Inspect the counter front bearing outer race for Reassembly
wear or damage. If wear or damage is found,
1. Install the counter middle bearing outer race and
remove the bearing outer race from the clutch
the shim selected according to the following
housing using the push puller : 5-8840-2802-0 (1)
instructions to the front case using the driver tool:
and the bearing remover: 5-8840-2757-0 (2).
5-8840-2863-0 (No. 90).
• Break the oil nozzle, and remove the outer race
by attaching claws of the puller at three points NOTE:
as shown in the diagram. • Firmly fit it in until it hits the end.
• When replacing the bearing, replace it together with
the inner race and outer race.
1
Selection of the shim for the counter shaft
• Firmly fit the counter middle bearing outer race
without a shim until it hits the front case.
Assemble the counter shaft ASM to the front
case that is firmly fitted with the outer race, and
then install the counter front bearing outer race
on the front side of the shaft.
Position the counter shaft in a vertical direction,
put a load of more than 49 N (5 kg / 11 lb) in a
vertical direction and rotate it about 10 times to
smoothen it out.
2
After smoothing out the bearing, measure the
thickness of the shim on the counter shaft side
using the shim selector: 5-8840-0194-0 and the
MFW75CSH002501 shim selector adapter kit: 5-8840-2794-0.
50. Remove the oil nozzle. Measuring instructions
51. Inspect the front oil seal for wear or damage. If a. Measure the thickness of the shim using the
wear or damage is found, remove it from the clutch shim selector and the contents in the shim
housing using a flat-blade screwdriver, etc. selector adapter kit (bridge extension: J-35284-
Inspect each part and if there is any wear, damage, or 19 (1), gauge pin: J-35284-8 (2), bridge: J-
other abnormalities, repair or replace the defective 35284-2 (4), and gauge cylinder: J-35284-4
parts. (5)).
52. Inspect the speedometer driven gear and driven b. Loosen the screw (3), put the gauge cylinder on
gear bushing for wear. the end surface of the counter front bearing
outer race, and then fasten it with the screw (3).
• Replace parts that are severely worn.
3
1
5 4
MFW75CSH002601
MFW75CSH007001

c. Set the bridge ASM upside down, assemble the Measured value mm (in) Types of selectable shim
bridge support leg: J-35284-3 (2) included in Greater than - Less than mm (in)
the shim selector and the bridge extension: J-
35284-19 (4) included in the shim selector 1.65 - 1.71 1.62
adapter kit, and then set them on the alignment (0.0650 - 0.0673) (0.0638)
surface of the rear front case. 1.71 - 1.77 1.68
d. Loosen the screw (3), put the gauge pin (1) on (0.0674 - 0.0696) (0.0661)
the seating surface of the counter front bearing
outer race, and then tighten the screw (3) 1.77 - 1.83 1.74
again. (0.0697 - 0.0720) (0.0685)
1.83 - 1.89 1.80
(0.0721 - 0.0744) (0.0709)
3
4
2 NOTE:
Selection of the shim that has the specified thickness
enables proper adjustment of a gap between the
counter middle bearing outer race and front case.
1 2
MFW75CSH002701
e. Measure the gap between the gauge cylinder

and gauge pin, and select a shim matching that
thickness. (The range of measured value
indicates the gap standard range of 0.03 to
0.09 mm (0.0012 - 0.0035 in) at the time of
shim assembly.))
LNW23DSH009701
Measured value mm (in) Types of selectable shim
Greater than - Less than mm (in) f. Remove the counter middle bearing outer race
from the front case using the driver tool: 5-
1.17 - 1.23 1.14 8840-2863-0 (No. 79), assemble the selected
(0.0461 - 0.0484) (0.0449) shim, and then firmly fit the counter middle
1.23 - 1.29 1.20 bearing outer race again using the driver tool:
(0.0485 - 0.0507) (0.0472) 5-8840-2863-0 (No.90).
1.29 - 1.35 1.26

(0.0508 - 0.0531) (0.0496)
1.35 - 1.41 1.32
(0.0532 - 0.0555) (0.0520)
1.41 - 1.47 1.38
(0.0556 - 0.0578) (0.0543)
1.47 - 1.53 1.44
(0.0579 - 0.0602) (0.0567)
1.53 - 1.59 1.50
(0.0603 - 0.0625) (0.0591)
1.59 - 1.65 1.56
(0.0626 - 0.0649) (0.0614)

2. Install the new oil nozzle (1) to the clutch housing. 5. Install the oil port cover.
• Tighten the bolt (1) on the upper side and then
tighten the bolt (2) on the lower side.
1
MFW75CSH006401
3. Install the counter front bearing outer race.

• Firmly fit the outer race using the driver tool: 5-
8840-2863-0 (No.72). 2
MFW75BSH001301
NOTE: 6. Assemble the reverse idle gear, reverse idle
• Firmly fit it in until it hits the end. needle bearing (2 pieces) and thrust washer to the
• When replacing the bearing, replace it together with reverse idle shaft, and then fix them with the pin.
NOTE:
Install the one with shorter reverse idle gear's boss to
face the front side of the vehicle.
MFW75CSH002801
4. Install the front oil seal to the clutch housing.

Inspect the oil seal for wear and damage. If wear MFW75CSH007101
or damage is found, replace it with a new one,
apply gear oil on the external circumference of the 7. Install the counter shaft ASM, input shaft ASM,
oil seal, and firmly fit the oil seal into the clutch reverse idle shaft ASM, and gear control (lower) to
housing using the driver tool: 5-8840-2863-0 (No. the clutch housing.
65) until it is flush with the end surface.
• 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.

• Use the belt with the tightening function, such
as a lashing belt to firmly tighten the counter 1
shaft ASM and input shaft ASM by winding
them together at more than 2 positions to
prevent them from falling.
2
MFW75CSH002201
9. Fix the screen ASM (2) to the oil pump case ASM
(1).
• Tighten the bolt (3) at its specified torque.
MFW75CSH002301
• Pass the tip of the input shaft through the clutch
housing, and install the reverse idle shaft ASM
before the input front bearing section is
embedded in the clutch housing.
NOTE:
Be cautious not to drop the gear control (lower) while 1
lifting it.
2
3
MFW75CSH000501
MFW75CSH002401
8. Connect the oil pump hose.

• Connect the hose (2) between the oil pump
ASM and oil pump case ASM and the reverse
idle shafts, and fix it with the clamp (1).
NOTE:
Insert the hose until it hits the pipe.

10. Install the gear control (upper). 13. Install the reverse idle shaft bolt.
• Insert a thin rod in the bolt hole at the bottom
section of the vehicle and adjust the reverse
idle shaft's bolt hole to its center. After the
upper part flange bolt is seated, tighten the
upper and lower bolts at its specified torque.
NOTE:
The flange bolt at the upper section of the vehicle is
used to fix the position. Note that, if the upper and
lower bolts are mis-assembled, there will be no side
clearance for the reverse idle gear.
MFW75CSH003301
11. Install the relay lever ASM.

• Install the relay lever to the groove of the gear
control.
• Apply LOCTITE 242 or equivalent to 4 to 6
threaded sections from the tip of the thread and
tighten.
NOTE:
When installing the relay lever ASM, make sure that the
snap ring of the relay lever shaft is installed in an
outward direction. MFW95CSH001401
14. Install the 6th needle bearing.

• Measure the collar external diameter (a), then
select and install a needle bearing that
corresponds to the collar external diameter of
φ49.977 - 49.999 mm (1.9676 – 1.9684 in) or
φ50.000 - 50.014 mm (1.9685 – 1.9691 in).
NOTE:
• When measuring the collar external diameter, press
fit it into the input shaft before measuring.
• If the clearance between the collar external
diameter and the needle bearing inner diameter is
improper, it may cause the gears to drop out.
MFW75CSH003401
12. Install the front case.

• Apply LOCTITE FMD127 or equivalent to the
alignment surface of the front case and clutch
housing, and then mount it to the clutch
housing.

d. Firmly insert the sleeve until the ball is put in
the ball groove on the sleeve while pushing in
the ball (2), block (3) and spring (4).
1
2
1
a 5
MFW95CSH001001
Legend
1. Collar
MFW75CSH006601
15. Install the 6th gear and 6th block ring. 17. Install the clutch hub ASM to the input shaft with
16. Assemble the 5th-6th clutch hub ASM. the 5th-6th shift arm being assembled to the
a. Install the block and spring to the clutch hub. sleeve.
b. There are 3 ball grooves in the sleeve. Align the NOTE:
phase to put the ball at the center of the ball
• Be cautious when assembling, as the detent spring
groove.
and detent ball may suddenly jump out if the sleeve
• When re-using, align the alignment mark is removed from the 5th-6th clutch hub ASM.
placed during disassembly and assemble it.
• Align the clutch hub's insert groove with the block
ring's protrusion, and then install.
MFW45DSH006401
c. Insert the sleeve (1) into the clutch hub (5) until MFW75CSH002901
it lightly touches the block.
18. Tap the spring pin into the 5th-6th shift arm.
19. Install the snap ring at the input shaft rear side.
20. Install the 6th counter gear.
21. Install the collar.
NOTE:
There is no particular assembly direction.
22. Install the 5th block ring.


23. Install the 5th dog clutch. 31. Apply BESCO L-2 grease or equivalent to the lip
24. Install the output shaft front bearing outer race to section and gear oil or engine oil to the outer
the rear case using the driver tool: 5-8840-2863-0 circumference, and then install the rear oil seal (4)
(No. 100). to the rear cover ASM (3) using the grip: 5-8840-
0007-0 (1), the oil seal installer: 5-8840-2871-0 (2)
NOTE: and the oil seal installer: 5-8840-2781-0 (5).
• Firmly fit it in until it hits the end.
• When replacing the bearing, replace it together with 1
a 4
MFW75CSH006901
Legend
(a) 32 mm (1.26 in)
MFW75CSH002101 32. Firmly fit the output shaft rear bearing outer race
25. Install the magnet. and the shim selected according to the following
instructions to the rear cover using the bearing
26. Apply LOCTITE FMD127 or equivalent to the
installer: 5-8840-2184-0.
mating surface of the front case and rear case, and
then install the rear case. NOTE:
Tightening torque: 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft) • Firmly fit it in until it hits the end.
27. Install the pilot bearing to the input shaft. • When replacing the bearing, replace it together with
28. Install the output shaft rear bearing inner race to
the output shaft using the bearing installer: 5-8840- Selection of the shim for the output shaft
2874-0.
• Put a load of more than 49 N (5 kg / 11 lb)
NOTE: toward the output shaft bearing's shaft direction
When replacing the bearing, replace it together with the and rotate about 10 times.
inner race and outer race. After smoothing out the bearing, measure the
thickness of the shim using the shim selector:
29. Install the output shaft front bearing inner race to 5-8840-0194-0 and the gauge pin: 5-8840-
the output shaft using the bearing installer: 5-8840- 2873-0.
2874-0. Measuring instructions
a. Measure the thickness of the shim using the
NOTE: gauge pin: 5-8840-2873-0 (2) and the contents
When replacing the bearing, replace it together with the in the shim selector (bridge ASM: J-35284-1 (1)
inner race and outer race. and gauge cylinder: J-35284-4 (4)).
30. Install the output shaft.


b. Loosen the screw (3), put the gauge cylinder on e. Measure the gap between the gauge cylinder
the end surface of the output shaft rear bearing and gauge pin, and select a shim matching that
outer race, and then fasten it with the screw (3). thickness. (The measured value indicates the
preload specified range of 0.03 to 0.09 mm
2 (0.0012 - 0.0035 in) at the time of shim
assembly.))
3
1 Measured value mm (in) Types of selectable
Greater than - Less than shim mm (in)
1 1.17 - 1.23 1.26
(0.0461 - 0.0484) (0.0496)
1.23 - 1.29 1.32
(0.0485 - 0.0507) (0.0520)
1.29 - 1.35 1.38
(0.0508 - 0.0531) (0.0543)
1.35 - 1.41 1.44
4 (0.0532 - 0.0555) (0.0567)
1.41 - 1.47 1.50
MFW75CSH003001
(0.0556 - 0.0578) (0.0591)
c. Set the bridge ASM upside down and set it on
the alignment surface of the rear cover. 1.47 - 1.53 1.56
(0.0579 - 0.0602) (0.0614)
d. Loosen the screw (1), put the gauge pin (2) on
the seating surface of the output shaft rear 1.53 - 1.59 1.62
bearing outer race, and then tighten the screw (0.0603 - 0.0625) (0.0638)
(1) again. 1.59 - 1.65 1.68
(0.0626 - 0.0649) (0.0661)
1.65 - 1.71 1.74
(0.0650 - 0.0673) (0.0685)
1.71 - 1.77 1.80
(0.0674 - 0.0696) (0.0709)
1.77 - 1.83 1.86
(0.0697 - 0.0720) (0.0732)
NOTE:
Selection of the shim that has the specified thickness
enables proper preload adjustment between the output
shaft rear bearing outer race and rear cover ASM.
1
2
MFW75CSH003101

37. Install the rear cover ASM.
alignment surface of the rear case and rear
cover ASM, and then install the rear cover.
38. Install the PTO cover.
• Install the transmission, so that it stays
horizontal.
alignment surface of the front case PTO cover,
and then install the PTO cover via the packing.
NOTE:
Since sealing agent is applied to the bolts, completely
LNW23DSH009701 remove the sealing agent at the front case threaded
area, and use new bolts with sealing agent.
33. Install the output counter gear.
When re-using the bolts, apply LOCTITE 242 or
NOTE: equivalent or equivalent to them.
Install it with the end surface that has the oil groove
39. Apply gear oil to the O-ring and install the dummy
facing toward the rear side.
sensor cap and O-ring.
34. Install the counter end bearing. Tightening torque: 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
NOTE: 40. Install the speedometer driven gear ASM.
Be cautious of the assembly direction. • Apply oil (BESCO GEAR OIL SH 80W-90 or
equivalent) to the inner side of the oil seal lip
35. Install the counter end nut.
(1), make the lip section turn downward, and
• After having the gear double locked and then firmly fit it to a depth of 15.0 mm(0.59 in)
tightened at its specified torque, crimp the nut while avoiding deformation. At that time, apply
in alignment with the counter shaft's 2 grooves. oil to the external circumference of the oil seal.
NOTE: Assembly Standard

Depth of oil seal
The counter end nut is a left-hand thread. 15.0 mm (0.59 in)
36. Apply BESCO L-2 grease or equivalent to the gear

tooth surface, and then install the speed meter
drive gear (1).
15mm
(0.59 in)
1
1
MFW85CSH000101
MFW75CSH006201

• Install the bushing to the driven gear.
Apply grease to the O-ring (1) and install the
bushing. In addition, fill the grease groove (2)
with grease (BESCO L-2, BESCO L-3 grease
or equivalent).
1
1
2
MFW75BSH002001
Legend
1. Sealing agent coating area (within the length of
thread)
MFW85CSH000201
46. After completely removing the sealing agent on the
• Assemble the speedometer driven gear, fit it to threaded area of the detent ASM (4 positions),
the rear cover with the set bolt, and then install apply LOCTITE 242 or equivalent and install it.
the protector.
Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
47. Set the shift position to the neutral position, apply
41. Install the parking brake cable bracket to the LOCTITE FMD127 or equivalent to the mating
transmission case. surface of the front case control box, and then
install the interlock plate and control box.
42. Install the parking brake ASM.
• Refer to "Parking Brake" in Section 4D, Parking NOTE:
Brake. • Since bolts with sealing agent is used, completely
43. Apply gear oil to the O-ring, and then install the remove the sealing agent at the front case threaded
parking brake drum, flange ASM and O-ring. area, and use new bolts with sealing agent.
44. After having the gear double engagement and When re-using the bolts, apply LOCTITE 242 or
tightening the main end nut at its specified torque, equivalent to them.
crimp the nut in alignment with the output shaft's 2
grooves.
45. Install the backup light switch.
• Install the backup light switch using the switch
wrench (5-8840-2875-0).
• Remove the old sealing agent on the switch
threaded area, apply new sealing agent within
the illustrated range, and then assemble.
Sealing agent: LOCTITE 242 or equivalent

• Be cautious in positioning the stud bolt in the
diagram.
4H Engine
MFW95CSH001101
6H Engine
MFW95CSH001201
48. Install the shift block, release bearing, clutch shaft

and shift fork.
• Refer to "Clutch ASM" in Section 5E Clutch
(MZW).
49. Apply gear oil to the O-ring, and then install the
drain plug and O-ring.
50. Apply gear oil to the O-ring, and then install the
filler plug and O-ring.
51. Connect the connector of sensor to the
transmission harness.
• Neutral switch
• Backup light switch

List of Tightening Torques
a b
f
d
l
g
k
m
j i
n
p
h
e q
r
o
t
s
MFW95CLF000501
Legend
(a) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft) (l) 15 N⋅m (1.5 kg⋅m / 11 lb⋅ft)
(b) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft) (m) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(c) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft) (n) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)
(d) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) (o) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(e) 148 N⋅m (15.1 kg⋅m / 109 lb⋅ft) (p) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(f) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) (q) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(g) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) (r) 132 N⋅m (13.5 kg⋅m / 98 lb⋅ft)
(h) 539 N⋅m (55.0 kg⋅m / 398 lb⋅ft) (s) 785 N⋅m (80.0 kg⋅m / 579 lb⋅ft)
(i) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) (t) 15 N⋅m (1.5 kg⋅m / 11 lb⋅ft)
(j) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(k) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
Rear Oil Seal

Components
MFW75BSF000401
Legend
1. Oil Seal 2. Rear Cover
Removal
1. Remove the rear cover from the rear case. 1
• Refer to "MZW Transmission" in this section.
2. Remove the oil seal using a flat-blade screwdriver,
etc.
2
Installation
1. Apply gear oil or engine oil to the external 3
circumference of new oil seal, and firmly fit the oil
seal to the rear cover.
a 4
lip section of the oil seal.
5
• Install the rear oil seal (4) to the rear cover ASM
(3) using the grip: 5-8840-0007-0 (1), the oil
seal installer: 5-8840-2871-0 (2) and the oil seal
installer: 5-8840-2781-0 (5). MFW75CSH006901
Legend
NOTE:
Be careful not to damage the lip section of the oil seal. (a) 32 mm (1.26 in)
2. Install the rear cover.

• Refer to "MZW Transmission" in this section.
Input Shaft
Components
1
2
4
5
6
7
8
MFW85CSF000101
Legend
1. Snap Ring 5. 3rd Gear
2. Input Front Bearing 6. 4th Gear
3. Input Shaft 7. Input Rear Bearing
4. Oil Pump ASM 8. Collar
Disassembly 2. Remove the input front bearing using a press.

1. Remove the snap ring for fixing the bearing using
two flat-blade screwdrivers.
• Protect the snap ring with a rag, etc. so that it
does not pop out.
MFW75CSH003701
3. Remove the collar, input front bearing and 4th gear

using a press.
MFW75CSH003501 copper plate, etc. placed on the shaft end.

Reassembly
1. Install the oil pump ASM.
NOTE:
Apply gear oil onto the internal diameter of the case
and the entire circumference of front and rear side end
surfaces.
• Align the protruding portion of the oil pump gear

(2 opposite sides) (1) with the notch section (2)
of the input shaft (2 opposite sides) and install.
MFW75CSH003801 2
4. Remove the 3rd gear using the separator and

press.
copper plate, etc. placed on the shaft end. 1
MFW75CSH000701
• After firmly fitting the gear, check that the oil

pump ASM rotates smoothly.
2. Firmly fit the 3rd gear with a press, using the
installer: 5-8840-2345-0.
MFW75CSH003901
5. Remove the oil pump ASM.

If wear, damage, or other abnormalities are found in the
disassembled parts, repair or replace the defective
parts.
6. Check cross-section of each gear for breakage,
damage or wear. If an abnormality is detected,
replacement of gears is needed.
7. Inspect each bearing for the following items. If an
abnormality is detected, replacement of gears is
needed. MFW75CSH004001
• Smoothness of rotation
3. Firmly fit the 4th gear and input bearing with a
• Abnormal noise press, using the installer: 5-8840-2345-0.
• Abnormalities in appearance such as damage, • Firmly fit so that the brim of the inner race is
rust, etc. facing toward the rear side.
• Abnormal play in the thrust direction
NOTE:
• Be cautious of the assembly direction.

• Firmly fit while aligning the center of the inner race
and the roller section.
MFW75CSH004301
6. Install the snap ring for fixing the bearing, using a

MFW75CSH004101
piece of wood, etc.
4. Firmly fit the collar with a press, using the gear NOTE:
installer: 9-8522-0033-0. When installing the snap ring, replace the snap ring
with a new one if it is deformed or damaged, and make
sure it is installed firmly.
MFW75CSH004201
5. Firmly fit the input front bearing with a press, using

the installer: 5-8840-2345-0. MFW75CSH003601
• Firmly fit so that the brim of the inner race is
facing toward the front side.
NOTE:
• Be cautious of the assembly direction.
• Firmly fit while aligning the center of the inner race
and the roller section.
Counter Shaft
Components
1 2
3
4
5
6
7
8
9
10
17
18
19 11
20 12
21 13
22
14
23 15
24 16
25
26
27
28
MFW75CMF000101
Legend
1. Snap Ring 15. 2nd Needle Bearing
2. Counter Front Bearing Inner Race 16. Counter Shaft
3. Sleeve and Reverse Clutch Hub 17. Oil Pump Case ASM
4. Reverse Needle Bearing 18. 3rd Gear
5. Reverse Gear 19. 3rd Needle Bearing
6. Snap Ring 20. 3rd Inside Ring
7. Collar 21. 3rd Outside Ring
8. 1st Needle Bearing 22. 3rd Block Ring
9. 1st Gear 23. 3rd-4th Clutch Hub ASM and Sleeve
10. 1st-2nd Clutch Hub ASM and Sleeve 24. 4th Block Ring
11. 2nd Block Ring 25. 4th Gear
12. 2nd Outside Ring 26. 4th Needle Bearing
13. 2nd Inside Ring 27. Collar
14. 2nd Gear 28. Counter Middle Bearing Inner Race

Disassembly 8. For protection of the oil hole, place a copper plate,
etc. on the shaft end, and remove the 1st-2nd
1. Remove the sleeve of the reverse clutch hub.
clutch hub ASM and sleeve, 2nd block ring, 2nd
2. Remove the snap ring using snap ring pliers. outside ring, 2nd inside ring and 2nd gear at the
3. For protection of the oil hole, place a copper plate same time using a press.
that is smaller inner diameter of the inner race, on
the shaft end, and remove the counter front
bearing inner race and reverse clutch hub using
the gear puller (1) .
MFW75CSH000901
9. Disassemble the 1st-2nd clutch hub ASM and

sleeve.
MFW75CSH005901
• Perform the disassembly after removing the
snap ring at the 1st gear side.
4. Remove the reverse gear and reverse needle
• Place an alignment mark beforehand when re-
bearing.
using the clutch hub and sleeve.
5. Remove the snap ring using snap ring pliers.
• Wrap the detent ball with rag, etc. when
6. For protection of the oil hole, place a copper plate, disassembling, so as to avoid the detent ball
etc. on the shaft end and remove the collar and 1st from jumping out.
gear at the same time using a press.
NOTE:
Note that a different spring is used for Smoother and
manual transmission.
MFW75CSH000801
7. Remove the 1st needle bearing.


NOTE:
Note that a different spring is used for Smoother and
1 manual transmission.
2
6
5 1
5
4
3
4
2
3
MFW75CSH006501
Legend
1. Snap ring
2. Clutch hub
MFW45DSH005501
3. Sleeve
4. Ball Legend
5. Block 1. Clutch hub
6. Spring 2. Sleeve
3. Ball
10. Remove the 2nd needle bearing. 4. Block
11. Remove the counter middle bearing inner race, 5. Spring
collar, 4th needle bearing, 4th gear, 4th block ring,
3rd-4th clutch hub ASM and sleeve, 3rd block ring, 13. Remove the 3rd needle bearing.
3rd outside ring, 3rd inside ring, and 3rd gear at 14. Remove the oil pump case.
the same time using a press.
Inspection
Inspect each part. If any wear, damage, or other
abnormalities are found, repair or replace the defective
parts.
1. 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
MFW75CSH001001
12. Disassemble the 3rd-4th clutch hub ASM and

sleeve.
• Place an alignment mark beforehand when re-
using the clutch hub and sleeve.
• Wrap the detent ball with rag, etc. when
disassembling, so as to avoid the detent ball
from jumping out.

2. Inspect the inner diameter of the gear. • Replace the main shaft if the measured value
• Measure the inner diameter of each gear. exceeds the standard value.
Standard value: 0.015 mm (0.0006 in)
• Replace the gear if the measured value
exceeds the standard value.
mm (in)
Standard value
6th gear 50.009 - 50.025
(1.9689 - 1.9694)
Output shaft 48.009 - 48.025
(1.8902 - 1.8907)
4th gear 63.010 - 63.029
(2.4808 - 2.4814)
3rd gear 63.010 - 63.029
(2.4808 - 2.4814)
2nd gear 63.010 - 63.029
(2.4808 - 2.4814)
MFW45DSH005901
1st gear 63.010 - 63.029
4. Inspect the synchromesh mechanism.
(2.4808 - 2.4814)
• Inspect components and repair minor stepped
Reverse gear 55.009 - 55.025 wear and damage using an oil stone or pencil
(2.1658 - 2.1663) grinder.
MFW45DSH006001
MFW45DSH005801 5. Measure the gap between the block ring and dog
3. Inspect the fluctuation of the main shaft. gear using the feeler gauge.
• Measure the main shaft for warps. • Replace the block ring if the measured value
exceeds the standard value.
mm (in)
Standard value
1.03 - 2.60
4th/5th/6th
(0.0406 - 0.1023)
1.00 - 2.50
2nd/3rd
(0.0394 - 0.0984)
LNW25CSH008201 LNW25CSH045101
8. Measure the gap (A) between the clutch hub and

the budging section of the block ring.
• Replace the block and clutch hub if the
measured value exceeds the standard value.
1
mm (in)
Standard value 4.30 - 4.70 (0.1693 - 0.1850)
2
1
3 A 2
LNW25CSH008301
Legend
1. Block ring
2. Outside ring
3. Inside ring
6. Inspect the sliding section, spline section, insert

section and insert groove, etc. of the clutch hub
and sliding sleeve for wear and damage.
7. Measure the looseness (on the external LNW25CSH051301
circumference of the clutch hub) in the spline
Legend
rotational direction.
1. Block ring
• Replace them if the measured value exceeds 2. Clutch hub
the standard value.
mm (in)
Standard value 0 - 0.16 (0 - 0.0062)

Reassembly d. Firmly insert the sleeve until the ball is put in
• Clean each part thoroughly.
1. Install the oil pump case.
1
NOTE:
2
• Apply gear oil onto the internal diameter of the case
and the entire circumference of front and rear side 3
end surfaces.
5
• Pay attention to the assembling direction.
4
2. Assemble the 3rd-4th clutch hub ASM and sleeve
using the following procedure:
a. Install the block and spring to the clutch hub.
b. There are 3 ball grooves in the sleeve. Align the
phase to put the ball at the center of the ball
groove.
• When re-using, align the alignment mark
LNW25CSH038601
3. Apply BESCO L-2 grease or equivalent to the 3rd

needle bearing, and then install the needle
bearing.
4. Apply gear oil onto the gear thrust surface and
install the 3rd gear.
5. Install the 3rd inside ring, 3rd outside ring and 3rd
block ring in the manner that the claw part of the
3rd outside ring can be fit into the dog gear hole on
the 3rd gear. In this case, fully apply gear oil to the
inside ring, outside ring, and block ring sliding
surface.
6. Mount the 3rd-4th clutch hub ASM and sleeve by
fitting 6 claw areas on the 3rd inside ring in 6 holes
on the hub and press them in with a press using
the installer: 5-8840-2345-0 (1).
MFW45DSH006401
c. Insert the sleeve (1) into the clutch hub (5) until NOTE:
it lightly touches the block. Inspect the entire circumference to see if the ring or
cone is not improperly mounted.
MFW75CSH004401 MFW75CSH004601
7. Install the 4th block ring. 10. Assemble the 1st-2nd clutch hub ASM and sleeve
8. Apply BESCO L-2 grease or equivalent to the 4th using the following procedure:
needle bearing and apply gear oil to the 4th gear a. Install the block and spring to the clutch hub.
thrust surface, and then firmly fit the needle b. There are 3 ball grooves in the sleeve. Align the
bearing and collar with a press using the installer: phase to put the ball at the center of the ball
5-8840-2345-0 (1). groove.
• When re-using, align the alignment mark
MFW75CSH004501
9. Firmly fit the counter middle bearing inner race

with a press, using the installer: 5-8840-2345-0. MFW45DSH006401
NOTE: c. Insert the sleeve (1) into the clutch hub (3) until
When replacing the bearing, replace it together with the it lightly touches the block.
inner race and outer race. d. Firmly insert the sleeve until the ball is put in

e. Install the snap ring (2). 15. Apply BESCO L-2 grease or equivalent to the
needle bearing and apply gear oil to the gear thrust
4 surface, and then firmly fit the 1st gear, 1st needle
3
bearing and collar with a press using the installer:
5-8840-2345-0 (1).
2
5
6
1
MFW75CSH005101
11. Apply BESCO L-2 grease or equivalent to the 2nd

needle bearing, and then install the needle
bearing.
MFW75CSH004801
12. Apply gear oil onto the 2nd gear thrust surface,
and then install the gear. 16. Install the snap ring using snap ring pliers.
13. Install the 2nd inside ring, 2nd outside ring and 2nd NOTE:
block ring. In this case, fully apply gear oil to the Replace the snap ring with a new one if it is deformed
inside ring, outside ring, and block ring sliding or damaged and make sure it is mounted firmly.
surface.
14. Firmly fit the 1st-2nd clutch hub ASM and sleeve 17. Apply BESCO L-2 grease or equivalent to the
with a press, using the installer: 5-8840-2345-0. reverse needle bearing, and then install the needle
bearing.
NOTE: 18. Apply gear oil onto the reverse gear thrust surface,
Inspect the entire circumference to see if the ring or and then install the gear.
cone is not improperly mounted.
19. Firmly fit the sleeve and reverse clutch hub with a
press, using the installer: 5-8840-2345-0.
MFW75CSH004701
MFW75CSH004901
20. Firmly fit the counter front bearing inner race with a
press, using the bearing installer: 5-8840-2244-0.

NOTE:
When replacing the bearing, replace it together with the
inner race and outer race.
MFW75CSH005001
21. Install the snap ring using snap ring pliers.
NOTE:
Replace the snap ring with a new one if it is deformed
or damaged and make sure it is mounted firmly.
Gear Control
Components
3
6
2
5 8
13
1
7
4
14
10 1
1
12
9 1
11
MFW85CLF000401
Legend
1. Spring Pin 8. 5th-6th Gear Rod
2. Reverse Block 9. 3rd-4th Shift Arm ASM
3. Reverse Sub-rod 10. 1st-2nd Shift Arm ASM
4. 3rd-4th Block ASM 11. Reverse Rod
5. Stopper Pin 12. Reverse Sub-block
6. 1st-2nd Block ASM 13. Reverse Shift Arm
7. 5th-6th Gear Block 14. Transmission Front Case

Disassembly
1. Remove the 1st-2nd gear block ASM.
2. Remove the 5th-6th gear block and 5th-6th rod
from the 3rd-4th block.
• Pull out the spring pin from the 5th-6th block,
and remove the 5th-6th block from the 5th-6th
rod.
3. Pull out the reverse block's spring pin, and remove
the reverse sub-rod, and then the reverse block.
4. Remove the stopper pin from the reverse block.
5. Remove the 3rd-4th shift arm ASM.
6. Pull out the reverse shift arm's spring pin, and
remove the reverse shift arm.
7. Remove the 1st-2nd shift arm ASM.
8. Pull out the reverse sub-block's spring pin, and
remove the reverse sub-block from the reverse
rod.
9. Inspect each part of the shift mechanism. Repair
minor wear, bending and stepped wear. Replace it
if it is severely damaged or exceeds the standard
value.
• Bending, wear, or damage to the shift rod and
shift arm
• Thickness of the shift arm
- Measure the thickness of the tip of the shift
arm using a micrometer.
Thickness of the shift arm mm (in)

Standard value
Reverse 10.75 - 10.85 (0.4233 - 0.4271)
1st-2nd gear,
3rd-4th gear, 9.60 - 9.85 (0.3780 - 0.3877)
5th-6th gear
LNW25CSH013101

Reassembly • Firmly fit the spring pin until it is flush with the
tapping surface.
NOTE:
• Tap and firmly fit the spring pin in the direction of
• When assembling the block and arm to the shift
the diagram.
rod, be careful about the direction of the detent ball
groove.
MFW75CLF000401
1. Install the reverse sub-block to the reverse rod, 9. Install the 5th-6th rod and 5th-6th block to the 3rd-
and firmly fit the spring pin. 4th block ASM.
2. Install the 1st-2nd shift arm ASM. 10. Install the 1st-2nd block ASM.
3. Install the reverse shift arm, and firmly fit the spring
pin.
4. Install the 3rd-4th shift arm ASM.
5. Install the stopper pin to the reverse block.
6. Assemble the 3rd-4th block ASM to the reverse
block.
7. Install the reverse sub-rod to the reverse block via
the 3rd-4th block ASM, and firmly fit the spring pin.
8. Pass the 5th-6th rod through the 5th-6th block, and
firmly fit the spring pin.
Relay Lever
Components
3
7
6
5 4
MFW75CSF000101
Legend
1. Relay Lever Shaft 5. 3rd-4th Relay Lever
2. Relay Lever Block 6. Reverse Relay Lever
3. Snap Ring 7. Plain Washer
4. 1st-2nd Relay Lever
Disassembly
1. Remove the snap ring using snap ring pliers.
2. Remove the relay lever shaft.
3. Remove the 1st-2nd relay lever, 3rd-4th relay
lever, reverse relay lever and plain washer.
Reassembly
1. Install the 1st-2nd relay lever, 3rd-4th relay lever,
reverse relay lever and plain washer.
2. Install the relay lever shaft.
• Apply BESCO L-2 grease or equivalent and
then assemble.
3. Install the snap ring using snap ring pliers.
NOTE:
Use new snap rings.
Control Box
Components
6H Engine
3 6
4
7
5
23
9
22
20
12 8 10
21 7
19 13
17
18
17
16
14 11
15
MFW75CLF000501
Legend
1. Link Rod 13. Plain Washer
2. Select External Lever 14. Spring Pin
3. Washer 15. Select Internal Lever
4. Oil Seal 16. Spring
5. Neutral Switch 17. Plain Washer
6. Select Relay Lever 18. Shift Internal Lever
7. O-ring 19. Spring
8. Bushing 20. Spring Pin (Spring Stopper)
9. Control Box 21. Spring Stopper
10. Shift Shaft 22. Spring Pin (Shift Shaft)
11. Power Assist ASM 23. Detent ASM
12. Oil Seal

4H Engine
14
13
12
19
15
11
16
10
17 18
20
9
6
5 8
4
3
2
1
21
26
7
23
22
28 24
25
27
MFW75CLF000601
Legend
1. Spring 15. O-ring
2. Plain Washer 16. Bushing
3. Shift Internal Lever 17. Bolt
4. Plain Washer 18. Oil Seal
5. Spring 19. Shift Shaft
6. Spring stopper 20. Pipe
7. Spring Pin (Spring Stopper) 21. Power Assist ASM
8. Control Box 22. Neutral Switch
9. Detent ASM 23. Bushing
10. Oil Seal 24. O-ring
11. Washer 25. Plain Washer
12. Select External Lever 26. Spring Pin (Shift Shaft)
13. Link Rod 27. Spring Pin
14. Select Relay Lever 28. Select Internal Lever

Disassembly 2. Apply gear oil to sliding surface and spline section
of the shift shaft. Apply grease to the detent groove
1. Remove the neutral switch and detent ASM.
on the spring stopper.
2. Remove the bolts (3 pieces) fixing the power assist
3. Insert the shift shaft into the control box while
ASM to the control box and the nut (1 piece)
assembling the spring stopper, spring (2 pieces),
tightening the shift shaft, and then remove the
plain washer (2 pieces) and shift internal lever.
power assist ASM.
3. Remove the link rod. NOTE:
4. Remove the nut fixing the select relay lever, and When inserting the shift shaft, be careful not to damage
then remove the select relay lever, plain washer, the oil seal.
O-rings (2 pieces) and bushings (2 pieces).
4. Align the pin hole on the shift shaft with the pin
5. Using a spring remover, remove the spring pin,
hole on the spring stopper, and then tap in the new
and then remove the select internal lever, select
spring pin (spring stopper) and spring pin (shift
external lever, and washer.
shaft).
6. Remove the spring pin (spring stopper) using
pliers. NOTE:
7. Remove the spring pin (shift shaft) using pliers. After tapping the spring pin in, approximately 7 mm
(6H engine) (0.28 in) of the head section of the spring pin must
8. Remove the bolt from the control box and punch remain.
out the spring pin (shift shaft) (4H engine).
5. Tighten the bolt. (4H engine)
9. Pull out the shift shaft, and then remove the spring
stopper, spring (2 pieces), plain washer (2 pieces) Tightening torque: 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
and shift internal lever. 6. Apply grease to the sliding area of the select
10. Remove the select lever shaft oil seal and shift external lever. Insert the select external lever and
lever shaft oil seal from the control box by washer into the control box, install the select
wrenching them with a screwdriver, etc. internal lever, and then punch out the new spring
If wear, damage or other abnormalities are found in the pin.
disassembled parts, repair or replace the defective
parts. NOTE:
11. Check for wear of the shift lever shaft, looseness When inserting the select external lever, be careful not
with the control box, and for motion that is not to damage the oil seal.
smooth. Replace if necessary.
7. Insert 2 bushings from the top and bottom into the
control box, assemble an O-ring to the select relay
Reassembly lever, and then insert them into the control box.
Assemble the O-rings and plain washers into the
1. Using the control box oil seal installer: 5-8840-
select relay lever and then install them using the
2245-0, install the shift lever shaft oil seal and
mounting nut.
select lever shaft oil seal on the control box.
Apply grease to the lip section of the oil seal. Tightening torque: 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
8. Install the link rod using the nut.
5-8840-2245-0
9. Mount the power assist ASM to the control box and
shift shaft.
Bolt
Nut
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.
MFW45DSH007101

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: ThreeBond 1141 or equivalent
MFW75BSH002001
Legend
1. Sealing agent coating area (within the half length
of thread)

6H Engine
a c
MFW75CLF000701
Legend
(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) (e) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) (f) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(c) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(d) 43 N⋅m (4.4 kg⋅m / 32 lb⋅ft)

4H Engine
MFW75CMF000301
Legend
(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) (e) 43 N⋅m (4.4 kg⋅m / 32 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) (f) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(c) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in) (g) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(d) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
MEMO
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Clutch (MZW) 5E-1
Clutch
(MZW)
TABLE OF CONTENTS
Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2
Description of Function and Operation . . . . . . . 5E-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-3
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-7
Clutch ASM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-15
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-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-40
List of Tightening Torques . . . . . . . . . . . . . . . . 5E-44
5E-2 Clutch (MZW)
Clutch System
1
2
D d
MFW85EMF000101
Legend
1. Clutch ASM 2. Clutch Disk
Facing dimensions
Engine type Clutch Size D (mm (in)) d (mm (in))

4HK1-TCS 14 inch 350 (13.78) 220 (8.66)
6HK1-TCN
6HK1-TCC 15 inch 380 (14.96) 240 (9.45)
6HF1-TCN
Clutch (MZW) 5E-3

Inspection
Remove air out from the clutch system
MFW75ELF000301
Legend
1. Reservoir Tank 4. Air Bleeder
2. Brake Pedal 5. Vinyl Pipe
3. Clutch Pedal
1. Pour clutch fluid (BESCO brake fluid super

(DOT3)) 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.
5E-4 Clutch (MZW)
MFW75ESH000301 MFW75ESH000401
2. Installing the vinyl pipe. b. Remove the air.

• Attach the vinyl pipe to the bleeder screw of the After pressing the pedal repeatedly, in this
clutch booster and place the other end of the condition, loosen the bleeder with a half turn to
pipe into a clear container containing roughly 1/ release the air. Tighten the bleeder prior to
3 of clutch fluid. 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. MFW75ESH000501
CAUTION:
Stop the engine and perform under conditions where
the booster does not operate.
Clutch (MZW) 5E-5

Inspect the clutch pedal free play
1. Lightly push in the clutch pedal using your hand 1
until resistance to movement is felt in order to
check the clutch pedal free play.
clutch pedal free play 50 - 70 mm (1.97 - 2.75 in)
a 2
MFW85ESH000201
1 Legend
1. Pedal box
2. Clutch pedal
Adjusting the clutch pedal free play

Outline of adjustment procedures
MFW75ESH000601 If the clutch pedal free play exceeds specifications,
stop the engine and adjust the clutch pedal free play
Legend
using the clutch booster and the clutch master cylinder.
1. Play amount of clutch pedal
1. Remove the clutch booster return spring.
2. Make sure that the parking brake is set and with 2. Loosen the push rod lock nut.
the engine idling; push the clutch pedal all the way 3. While pushing out the push rod, turn until it
in. becomes firm.
3. Shift the gear into 1st gear, slowly release the 4. From this position, loosen the push rod back
pedal and determine the distance (a) between the according to the number of turns shown below.
pedal stopper and the pedal box just prior to
engagement of the clutch.
Number of reversing turns of the clutch booster push
rod
Distance (a) between the pedal
38 mm (1.50 in) Assembly Standard 2 1/4 - 2 3/4
stopper and pedal box when
or more
clutch engages
5. Firmly tighten the lock nut and put on the return
spring.
6. Inspect the clutch pedal free play. If the amount of
play still exceeds specifications, adjust the clutch
master cylinder according to the following
instructions.
7. 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), or "Pedal Box ASM"
in Section 4A3 Brake Control System (Full Air).
8. Loosen the lock nut of the clutch master cylinder
push rod.
9. Turn until the push rod contacts the piston.
5E-6 Clutch (MZW)

10. From this position, turn it back 2/5 - 4/5 turn. Here, 4. Turn the clutch switch back a half turn.
the gap between the tip of the push rod and the 5. Tighten the lock nut.
piston is 0.5 - 1.0 mm (0.020 - 0.039 in).
11. Firmly tighten the lock nut and put on the return
spring. Tightening torque N⋅m (kg⋅m / lb⋅in)
13(1.3 / 113)
Number of reverse rotations for

the clutch master cylinder push 2/5 - 4/5
rod
Push rod gap 0.5 - 1.0 mm 1
(0.020 - 0.039 in)
2
2
1
1
3
3 4
5
4 MFW95ESH000201
Legend
1. Clutch switch
2. Threaded portion
5
3. Lock nut
4. Push rod
5. Clutch pedal
7
6
MFW75EMH000401
Legend
1. Push rod
2. Clutch shaft
3. Lock nut
4. Clutch booster
5. Lock nut
6. 0.5 - 1.0 mm (0.020 - 0.039 in)
7. Push rod
8. Clutch pedal
Adjust the clutch switch

1. Remove the connector of the clutch switch.
2. Loosen the lock nut.
3. Tighten until the tip of the threaded portion of the
clutch switch screw hits the receiving area on the
side of the clutch arm.
Clutch (MZW) 5E-7

Special Tool
Illustration Tool Number/ Description
1-8525-3022-0
Clutch pilot aligner
1852530220
1-8525-3011-0
Release lever aligner
1852530110
1-8525-3026-0
Release lever aligner
1852530240
5E-8 Clutch (MZW)
Clutch ASM
Components • For the 14 inch clutch, the installation of the strap
plate made by fastening rivets (for clutch cover
• The diagram shows the case for the 15 inch clutch.
side) and tightening hexagon socket head bolts
(for pressure plate side).
1 3
2 4
5
6 8
9
25
24
23
22
21
11
10
12
13
20
17
19 18 14
15
16
16
15
MFW75ELF000601
Legend
1. Clutch Disk 14. Clutch Shaft
2. Pressure Plate 15. Dust Seal
3. Clutch Cover ASM 16. Needle Bearing
4. Spring Seat (Pressure Plate Side) 17. Shift Fork
5. Clutch Spring 18. Washer
6. Spring Seat (Clutch Cover Side) 19. Shift Fork Set Bolt
7. Strap Plate 20. Release Bearing ASM
8. Clutch Cover Set Bolt 21. Lever Pin (for Lever Support)
9. Clutch Cover 22. Lever Support
10. Lock Plate 23. Return Spring
11. Support Nut 24. Release Lever
12. Check Hole Cover 25. Lever Pin (for Release Lever)
13. Key
Clutch (MZW) 5E-9

Disassembly • Fix the pressure plate and clutch cover in place
in 4 locations using dummy bolts for fixation of
1. After removing auxiliary components mounted to
the pressure plate, nuts, and washers.
the transmission and the clutch booster push rod,
support and stabilize the transmission using a
transmission jack. M10 × 1.25
Dummy bolt (1)
2. Remove the flywheel housing installation bolts and L = 150 mm (5.91 in) × 4 pieces
pull the transmission toward the rear of the vehicle.
3. Remove the clutch cover ASM. • Remove clutch cover set bolts on diagonal from
• Insert the clutch pilot aligner in the clutch disk. each other, in order, referring to the diagram.
(Prevents dropping of the clutch disk.)
Special Tool
Clutch pilot aligner
5 9 1
Parts number Spline small diameter
1-8525-3022-0 35.85 mm (1.4114 in)
7 3
12 11
4 8
2 10 6
MFW75ESH001601
MFW45ESH000201
Legend
1. Clutch pilot aligner
5E-10 Clutch (MZW)

4. Remove the clutch disk.
MFW45ESH000601
MFW45ESH000401
6. Remove the lock plate.
5. Remove the strap plate. 7. Using a dummy bolt or a press and a block of
• For 15 inch clutch: Release the lock on the wood, remove the support nut and separate the
clutch cover and pressure plate tightening bolts clutch cover and the pressure plate.
and remove the bolts.
CAUTION:
Make sure to compress the clutch spring for performing
the work.
MFW45ESH000501
• For 14 inch clutch: Remove the hexagon socket

head bolts on the side of the pressure plate and
separate the strap plate and pressure plate. As MFW45ESH000701
the clutch cover side is attached using rivets
(1), it is not to be disassembled. 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.
Clutch (MZW) 5E-11

17. Tap the opposite side of the clutch shaft's shaft 2. Inspect the pressure plate for cracks, scratches
lever with a copper rod. and deformation.
18. When the key is released from the shift fork,
remove the key and pull out the shaft.
Amount of deformation mm (in)
19. Remove the shift fork.
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.
4 3 2 1
MFW85ESH000101
Legend
1. Clutch shaft
2. Set bolt
MFW45ESH001101
3. Shift fork
4. Key 3. Measure the friction of the pressure plate.
20. Remove the dust seal.

21. Remove the needle bearing. Thickness of the pressure plate mm (in)
Size 14 inch 15 inch
Inspection of clutch cover ASM
Nominal
1. Inspect the clutch cover ASM. 31.0 (1.22)
Dimension
• Determine the friction of the contact surface Limit for use 30.0 (1.18)
between the support nut and clutch cover.
MFW45ESH001001
MFW45ESH001201
• In addition, inspect the whole clutch cover for
any problems such as abnormal wear and
cracks.
5E-12 Clutch (MZW)

Inspect the clutch disk • Insert a pilot aligner in the clutch disk, support
1. Inspect the damper spring and facing. both ends horizontally. For 14 to 15 inch from
the center of the clutch disk, make
• Inspect the damper spring for breakage and
measurement at positions 170 mm (6.69 in).
wear and tear.
• Inspect the facing surface for cracks, surface
hardening due to loss of combustion, oil Amount of fluctuation of
deposits, and loosening of rivets. the clutch disk mm (in)
14, 15 inch
Size
170 mm (6.69 in) position
Nominal Dimension 0.8 (0.031) or less
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) MFW45ESH001501
Size 14 inch 15 inch 4. Measure the play in the spline rotational direction
of the clutch disk.
Nominal 2.0 - 2.6 2.2 - 2.8
Dimension (0.079 - 0.102) (0.087 - 0.110) • 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 mm (in)

Assembly Standard Limit for use
1.0 (0.039) or less 2.0 (0.078)
MFW45ESH001401
3. Measure the fluctuation in the clutch disk.

Clutch (MZW) 5E-13
Clutch nominal size mm (in)

Size 14 inch 15 inch
Nominal
43.0 (1.69) 48.0 (1.89)
Dimension
Limit for use 44.0 (1.73) 49.0 (1.93)
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, "Timing Gears, Flywheel
and Flywheel Housing" in Section 1B Engine
Mechanical 6HK1 or "Flywheel" in Section 1B
Engine Mechanical 6HF1-CNG.
MFW45ESH001901
5E-14 Clutch (MZW)

8. Inspect the wear on the contact surfaces of the
shift fork.
Wear mm (in)
CAUTION:
Repair minor wear by polishing or sanding with the use
of an oil stone.
MFW85ESH001201
10. Inspect the release bearing to see if it slides

2 smoothly on the clutch housing.
3
1
MFW85ESH001101
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 and damage. MFW75ESH001001
• Inspect the clutch lever and shift fork contact Legend

surfaces of the release bearing for wear. 1. Release bearing ASM
• Inspect the release bearing inner diameter for
wear. 11. Inspect the clutch shaft for stepped wear,
• If an abnormality is detected, replacement of disproportionate wear and for looseness between
release bearing is needed. the clutch shaft and the needle bearing.
CAUTION:
As it is sealed with grease, do not clean nor wash. External shape of the
clutch shaft mm (in)
Nominal Dimension Limit for use
φ25.0 (0.984) φ24.5 (0.965)
CAUTION:
If there is a lot of wear or looseness, replace both the
shaft and the bearing.
Clutch (MZW) 5E-15

3. Install the release lever ASM to the pressure plate
using the lever pin (for release lever).
MFW75ESH001201
MFW45ESH002601
Reassembly Legend
1. Apply a thin layer of grease (ONE LUBER MO 1. Grease coating
No.2 (molybdenum disulfide) or equivalent) to
each of the lever pin sliding surface. 4. Install the spring seat and clutch spring to the
pressure plate.
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
1
1
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 2
MFW45ESH002701
Legend
1. Clutch spring
2. Washer
3. Spring seat
5E-16 Clutch (MZW)

5. Apply a thin layer of grease (ONE LUBER MO • Temporarily tighten the support nuts to an
No.2 (molybdenum disulfide) or equivalent) to the equal tightness.
contact area for the support nut on the clutch
cover.
MFW45ESH003001
7. Mount the strap plate to the pressure plate.

MFW45ESH002801
6. Attach the clutch cover to the pressure plate using

a press or a dummy bolt. Tightening torque N⋅m (kg⋅m / lb⋅ft)
a. Method for using a press 14, 15 inch 44 ( 4.5 / 33)
• Compress the clutch cover with a press until
the threaded portion of the lever support • For 15 inch clutch: After tightening each bolt at
protrudes above the upper surface of the the specified torque, crimp the lock nut on the
cover. clutch cover side and bend the lock plate on the
• Temporarily tighten the support nuts to an pressure plate side.
equal tightness.
1 2
MFW45ESH003101
MFW45ESH002901 Legend
b. Method for using a dummy bolt 1. Lock plate (folding)
2. Lock nut (crimp)
• Screw the dummy bolt into the pressure
plate. • For 14 inch clutch: Tighten the pressure plate
• Fix the dummy bolt in place using a wrench side using a hexagon socket head bolt.
and tighten the nut until the threaded portion 8. Apply grease (variant grease S or equivalent) to
of the lever support protrudes above the the spline grease groove.
upper surface of the clutch cover.
9. Insert the clutch pilot aligner in the clutch disk.
Clutch (MZW) 5E-17

Special Tool
Clutch pilot aligner mm (in)
Parts number Spline small diameter
5 9 1
1-8525-3022-0 35.85 (1.4114)
7 3
12 11
4 8
2 10 6
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.
MFW45ESH003201
10. Insert the clutch pilot aligner integrated with the

clutch disk into the pilot bearing. 3 1
MFW45ESH003401
1 Legend
1. Clutch cover
2. Pressure plate
3. Pressure plate protection bolt
MFW45ESH003301
Legend 13. Pull out the clutch pilot aligner.

1. Clutch pilot aligner • Do not strike the clutch pilot aligner with a
hammer, etc., to remove it.
11. Install the clutch cover ASM onto the flywheel.
14. Adjust the height of the release lever.
• Align the clutch cover knock hole (as shown in
the diagram) with the flywheel knock pin. • Place the release lever aligner on the flywheel
housing, and adjust the support nut so that
• Slowly and equally tighten the clutch cover set there is no gap between the center of the
bolts in a diagonal order as shown in the release lever aligner and the lever.
diagram.
• Dimension L between the end surface of the
flywheel housing and the end surface of the
Tightening torque N⋅m (kg⋅m / lb⋅ft) release lever (Error margin for misalignment:
0.3mm (0.0118 in))
14, 15 inch 44 ( 4.5 / 33)
VF43 Add Euro2-sec5E(secid4555)print.fm 18 ページ２００９年９月１８日　金曜日　午後３時４１分
5E-18 Clutch (MZW)

Special Tool 16. Tap the needle bearing into the clutch housing until
it reaches its specified position.
Release lever aligner mm (in)
• Direct the marking of the needle bearing toward
Clutch size Parts number L dimension the insertion side.
9 (0.35) 17. Fill the needle bearing and the space between the
15 inch 1-8525-3011-0
(center indent section) needle bearing and the dust seal with grease
(BESCO L-2, L-3 grease or equivalent). Orient the
29 (1.14)
14 inch 1-8525-3026-0 dust seal lip towards the outside to install it in its
(center indent section)
specified position.
1
2
MFW75ESH001401
MFW45ESH003501
Legend
Legend 1. Needle bearing
1. Release lever aligner 2. Dust seal
15. Fix the support nut into place with the lock plate. 18. Insert the clutch shaft into the clutch housing and
install the key.
Tightening torque N⋅m (kg⋅m / lb⋅in)

14, 15 inch 13 ( 1.3 / 113)
4 3 2 1
1 MFW85ESH000101
Legend
1. Clutch shaft
2. Set bolt
MFW45ESH003601 3. Shift fork
Legend 4. Key
1. Lock plate
19. Install the clutch shaft to the shift fork.
Clutch (MZW) 5E-19

• 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.

13(1.3 / 113)
1
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 MFW75ESH001301
contact surfaces (2 places) of the shift fork (as
shown in the diagram). Legend
1. Release bearing ASM
• Apply 1.0 g (0.035 oz) of grease (ONE LUBER
MO No.2 (molybdenum disulfide) or equivalent) 21. Apply roughly 1.5 g (0.053 oz) of grease (variant
to the release bearing return spring contact grease S or equivalent) to the tooth surface, tooth
surfaces (2 places) of the shift fork (as shown in tips, and tooth crevices of the spline for the top
the diagram). gear shaft.
• Do not get grease on the release BRG and 22. Mount the transmission ASM.
clutch housing sliding areas.
23. Support the transmission using a transmission
• Confirm that the release bearing return spring is jack, and while matching the inclination of the
firmly assembled to the shift fork. engine, slowly push the transmission into place
and install it in place using a bolt.
Tightening torque N⋅m (kg⋅m / lb⋅ft)

14, 15 inch 44(4.5 / 33)
MFW95ESH000301
Legend
1. Release bearing return spring
5E-20 Clutch (MZW)

Item Specifications
Clutch size (nominal) 14 inch 15 inch
Clutch type Dry single plate coil spring type strap drive
Control type With hydraulic clutch booster
Facing dimensions
φ350 (13.78) × φ220 (8.66) × φ380 (14.96) × φ240 (9.45) ×
(External × internal diameter × thickness -
φ4.5 (0.177) - 2 plates φ5.0 (0.197) - 2 plates
number of plates) (mm (in))
Clutch spring Set load (N (kg / lb)) 11768 (1200 / 2646) 13484 (1375 / 3032)
Diameter × stroke (mm (in)) of clutch booster
φ70 (2.76) × 35.8 (1.41) φ90 (3.54) × 35.8 (1.41)
power cylinder
6HK1-TCN
Engine type 4HK1-TCS 6HK1-TCC
6HF1-TCN
Clutch (MZW) 5E-21
Clutch Master Cylinder

A
8
2
Cross Section A-A
6 5 4
MFW85ELF000101
Legend
1. Cap 5. Piston ASM
2. Diaphragm Gasket 6. Gasket
3. Dust Cover 7. Stopper Bolt
4. Snap Ring 8. Reservoir Tank
5E-22 Clutch (MZW)

Components
1
2
7
6
5
MFW75ELF001001
Legend
1. Cap 5. Dust Cover
2. Diaphragm Gasket 6. Gasket
3. Piston ASM 7. Stopper Bolt
4. Snap Ring
Removal • Protect the disconnected section from intrusion of

dust or filth.
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.
Clutch (MZW) 5E-23
1 2
1
3
2 MFW75ESH001801 MFW75ESH002001
2. Remove the clutch master cylinder installation bolt

(1) behind the clutch pedal (2).
Disassembly
1 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 CAUTION:
MFW75ESH001901
• Use clutch fluid for cleaning.
3. Remove the clutch master cylinder.
• Do not remove the reservoir tank and the clamp.
• 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).
5E-24 Clutch (MZW)
1 2
4 3 2
3
Legend Legend
1. Secondary cup 1. Slit area
2. Primary cup 2. Cylinder body
3. Return spring 3. Return spring
4. Piston
5. Fix the cylinder body in a vise, and mount the
2. Measure the external diameter of the piston and stopper bolt via the gasket while pressing the
the gap between the piston and cylinder body. piston with a screwdriver, etc.
CAUTION:
mm (in) • Install the stopper bolt after confirming that the
Nominal Assembly Limit for stopper bolt installation hole is properly aligned with
Dimension Standard use the direction of the piston slit portion.
External • Be careful so that the bolt does not touch the valve
φ19.05 φ18.96 rod or the piston when installing the stopper bolt.
diameter —
(0.7500) (0.7464)
of piston • The stopper bolt may come in contact with the valve
0.04 - 0.125 0.15 rod if the piston is not sufficiently pushed into place.
Gap — • The stopper bolt may come in contact with the
(0.0016 - 0.0049) (0.0059)
piston if the piston is pushed in too far.
Reassembly
1. Attach the diaphragm gasket to the cap.
3 ( 0.3 / 26)
2. Install the cap to the reservoir tank.
3. Coat the inner surface of the cylinder body, the
6. Fit the snap ring into the groove of the cylinder
outer surface of the piston and the cup with clutch
body while pressing the piston.
fluid (BESCO brake fluid super (DOT3)).
7. Install the dust cover.
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.
Clutch (MZW) 5E-25

2. Tighten the clutch master cylinder installation bolt
from the cabin side.

64 ( 6.5 / 47)
5 4 3 2 1
MFW75ESH002701
Legend
1. Valve rod
2. Stopper volt installation position
3. Slit portion
4. Snap ring
5. Dust cover
2
MFW75ESH001901
Legend
Installation 1. Bolt
1. Install the clutch master cylinder ASM. 2. Clutch pedal
• Align the pedal box positioning pin (2) with the 3. Install the clutch hose to the clutch master cylinder
clutch master cylinder positioning hole (3). ASM.
• Align the tip of the push rod (1) with the center
indent section of the piston.
• Prevent load from being applied on the push Tightening torque N⋅m (kg⋅m / lb⋅ft)
rod (1). 26 ( 2.7 / 20)
1 2 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.
3
MFW75ESH002001
VF43 Add Euro2-sec5E(secid4555)print.fm 26 ページ２００９年９月１８日　金曜日　午後３時４２分
5E-26 Clutch (MZW)
3
2
6. Adjust the gap between the piston and push rod. Legend
• Refer to "Clutch System" in this section. 1. Lock nut
2. Clearance between piston and push rod
• After adjusting, check to make sure that the
3. Push rod
amount of play in the clutch pedal is within
4. Clutch pedal
specifications.
mm (in)
Item Dimensions
Cylinder internal diameter φ19.05 (0.7500)
Maximum stroke 38 (1.50)
Maintenance standards table

mm (in)
Item Nominal Dimension Assembly Standard Limit for use
Piston external diameter φ19.05 (0.7500) — φ18.96 (0.7464)
Gap between piston and cylinder — 0.04 - 0.125 (0.0016 - 0.0049) 0.15 (0.0059)
Clutch (MZW) 5E-27
Clutch Booster
12 13 14 1 2 3 4
11 10 9 8 7 6 5
MFW45EMF000101
Legend
1. Relay Piston (Valve Piston Section) 8. Oil Seal
2. Poppet Valve 9. Return Spring
3. Poppet Spring 10. Power Piston
4. Cylinder Body 11. Push Rod
5. Hydraulic Piston 12. Cup
6. Piston Cup Gasket 13. Cylinder Shell
7. Piston Cup Gasket 14. Relay Piston (Relay Piston Section)
Clutch booster primary specifications
Clutch size 14 inch 15 inch

Engine type 6HK1-TCN, 6HK1-TCC,
4HK1-TCS
6HF1-TCN
Power piston diameter × stroke (mm (in)) φ70 (2.76) × 35.8 (1.41) φ90 (3.54) × 35.8 (1.41)
Hydraulic piston diameter (mm (in)) φ19.80 (0.7795) φ19.80 (0.7795)
Push rod diameter (mm (in)) φ8 (0.31) φ8 (0.31)
Relay piston section diameter (mm (in)) φ16 (0.6299) × 3.6 (0.142) φ16 (0.6299) × 3.6 (0.142)
Valve piston section diameter (mm (in)) φ20.0 (0.787) φ23.5 (0.925)
5E-28 Clutch (MZW)

Components
11
12
1
2
3
4
5
6
7
8
9
10 13
14
15
16
17
18
27 19
20
21
22
23
24 33
32
25 31
28 26
30
29
MFW45EMF000201
Legend
1. Piston Cup Gasket 18. Push Rod
2. O-ring 19. Snap Ring
3. Relay Piston 20. Washer
4. Spring 21. O-ring
5. O-ring 22. Retainer ASM
6. Upper Valve Body 23. Piston Cup Gasket
7. Poppet Valve 24. Retainer
8. Poppet Spring 25. Spring
9. Gasket 26. O-ring
10. Connector 27. Cylinder Body
11. Collar 28. Spring Pin
12. O-ring 29. Push Rod
13. Cylinder Shell 30. Guard
14. Nut, Washer 31. Hydraulic Piston
15. Piston Cup Gasket 32. Piston Cup Gasket
16. Piston Plate 33. Piston Cup Gasket
17. O-ring
Clutch (MZW) 5E-29

Clutch booster
4 3 2 1
MFW45EMF000301
Legend
1. Clevis Pin 4. Air Pipe
2. Return Spring 5. Oil Pipe
3. Clutch Booster
Removal 2. Plug the removed pipes so that foreign material

does not get into them.
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.
MFW45ESH005801
5E-30 Clutch (MZW)

Disassembly 3. Remove the connector from the upper valve body
first, and then the gasket from the internal
1. After removing dirt and dust from the surface of the
circumferential groove of the upper valve body.
clutch booster, loosen the air bleeder screw of the
Next, remove the springs and poppet valves from
relay valve and remove the oil through the oil fill
inside the upper valve body. Remove the collars
opening.
and O-rings from the pipe insertion area.
MFW45ESH005901
MFW45ESH006101
Legend
4. When three screws are removed, the upper valve
1. Bleeder screw
body can be separated from the cylinder body.
2. Fix the stand for disassembly and assembly in a Remove the O-rings from the groove of the upper
vise, mount the clutch booster, and remove the valve body using a special needle.
guard and fluid system connector. Special Tool
Special Tool Needle: 910-21200 (BOSCH part number)
(φ70) 910-10691
Stand for disassembly (BOSCH part number)
and assembly: (φ90) 910-10690
(BOSCH part number)
MFW45ESH006201
5. Remove the spring.

6. Remove the O-ring.
7. Remove the collar.
MFW45ESH006001
Legend
1. Guard 9. 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 (MZW) 5E-31

Special Tool 13. By pulling up the push rod while holding down the
tabs on the cylinder shell, the piston plate ASM
Needle: 910-21200 (BOSCH part number)
can be removed from the cylinder shell ASM.
MFW45ESH006501
MFW45ESH006301
14. Add a special socket to a vise stand, insert the
10. Remove the cylinder shell installation bolt and push rod into the socket and fix it in place. Next,
separate the cylinder body and cylinder shell. remove the nut and then the piston plate and O-
rings.
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)
Needle: 910-21200 (BOSCH part number)
5E-32 Clutch (MZW)

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
φ16.0 (0.6299) φ15.93 (0.6271)
Gap between relay piston and body mm (in)

Assembly Limit for
Standard use
MFW45ESH006701
Relay piston section 0.04 - 0.09 0.11
17. Remove the hydraulic piston from the cylinder (0.0016 - 0.0035) (0.0043)
body. Valve piston section 0.1 - 0.25 0.3
18. Using a special tool needle, remove the piston cup (φ23.5 (0.925)) (0.0040 - 0.0098) (0.1181)
gasket from the hydraulic piston. Valve piston section 0.1 - 0.25 0.3
19. Remove the spring pin inserted in the intake and (φ20.0 (0.787)) (0.0040 - 0.0098) (0.1181)
exhaust path of the cylinder body.
MFW45ESH006801
MFW45ESH006901
Legend
Inspection
1. External diameter of piston
CAUTION:
After cleaning the disassembled parts well using 4. Measure the gap between the external diameter of
cleaning fluid, inspect each of the parts thoroughly. the hydraulic piston and the cylinder.
1. In particular, visually inspect the following areas for

wear, damage, deformation or other abnormalities. Piston diameter mm (in)
If an abnormality is found, repair or replace the
Nominal dimension Limit for use
part.
• Each spring φ19.80 (0.7795) φ19.76 (0.7780)
• Each piston, shell
Gap between piston and cylinder mm (in)
• Valve body, cylinder body
Assembly standard Limit for use
0.01 - 0.06 (0.0004 - 0.0023) 0.08 (0.0031)
Clutch (MZW) 5E-33
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-34 Clutch (MZW)

Reassembly
CAUTION:
Apply grease to the locations shown in the table and
diagram below.
Grease type Application locations

1 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)
2 Air master paste • Entire surface of piston cup gasket (No.15)
(Silicon grease can be used as an • Entire surface of O-rings (No.5, 17, 26)
alternative)
• Entire surface of gasket (No.9)
3 Rubber grease • Inside surface of cylinder body (No.27)
(Silicon grease can be used as an • Entire surface of hydraulic piston (No.31)
alternative) 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 tip, O-ring (No.21)
• Entire surface of the relay piston (No.3) relay piston area piston
cup gasket
• Installation groove of the guard (No.30) on the tip of the cylinder
body (No.27)
3 3 1 1 2
2
3 3
2 2
3 3 3
3
2 2 3
MFW45EMF000501
Legend
1. Silicon grease 3. Rubber grease
2. Air master paste
Clutch (MZW) 5E-35

1. Apply a thin layer of grease to the cylinder area of
the cylinder body.
2
3
4
1 5
6
MFW45ESH007501
Legend
MFW45ESH007301
1. Snap ring
Legend 2. Washer
1. Cylinder body 3. Retainer ASM
2. Rubber grease 4. Piston cup gasket
5. Retainer
2. Apply grease to the O-ring groove and piston cup 6. Cylinder body
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.
1 Special Tool
Cup insert guide 910-23280
(fluid pressure side): (BOSCH part number)
(atmosphere side): (BOSCH part number)
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: 910-21970
(BOSCH part number)
CAUTION:
Make sure to assemble the piston cup gasket and
retainer ASM in the correct direction.
5E-36 Clutch (MZW)

7. Assemble the piston cup gasket onto the external
circumference of the piston plate and the O-rings
into the internal circumference grooves.
3 2 1
MFW45ESH007601
Legend
1. Cup inserting tool
MFW45ESH007801
2. Cup
3. Piston Legend
1. Piston cup gasket
5. Apply grease to the piston cup gasket lip area and 2. Piston plate
the external circumference of the piston, and install 3. O-ring
the hydraulic piston to the cylinder body.
8. Add a special socket to the vise stand, insert the
CAUTION: push rod into the socket from the hydraulic piston
Pay attention to the direction when mounting the side and hold down the adapter area. Next, put the
hydraulic piston. piston plate into the adapter and tighten the nut.

25 (2.5 / 18)
Power Piston Push Rod

Side Side
4 3 2 1
MFW85ESH000301
Legend
1. Grease groove
MFW45ESH007901
4. Piston
9. After tightening the nut, tap the mesh area of the
6. Coat the external circumference of the piston nut with a punch to prevent it from loosening.
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. Punch interval 180° - 2 locations
Clutch (MZW) 5E-37
10. Place a special work platform on the vise stand, 13. Using a special tool, mount the piston cup gasket
place the shell ASM on it, and apply air master center aligned to the relay piston.
paste to the sliding surfaces of the power piston. Special Tool
11. Insert the piston plate inside the shell ASM and Cup insert guide 910-24905
attach the spring on top of the piston plate. (fluid pressure side): (BOSCH part number)
Special Tool
Plate stand: 910-10691 (BOSCH part number) (atmosphere side): (BOSCH part number)
12. Assemble the O-rings to the cylinder body, align

the alignment marks that were made during
disassembly, and install to the shell ASM.

Power piston diameter φ70 18 (1.8 / 13)
Power piston diameter φ90 25 (2.5 / 18)
5E-38 Clutch (MZW)

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
18. Install the poppet valve and the spring onto the
upper valve body and next, coat the gasket with air
MFW45ESH008401
master paste and assemble the connector.
15. Apply rubber grease to the relay piston insert area
of the cylinder body and install the relay piston.
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. MFW45ESH008701
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.

5 (0.5 / 43)
Clutch (MZW) 5E-39

19. Install springs into the intake and exhaust paths at
the tip of the cylinder body, apply air master paste
to the guard installation groove, and install the
guard.
MFW45ESH009101
Legend
1. Grease coating
MFW45ESH008801
3. Mount the air hoses and oil pipes.
4. Remove air from the clutch system.
Installation • Refer to "Clutch System" in this section.
1. Mount the clutch booster.

Transmission - Bracket φ70 53 (5.4 / 39)
(installation bolt) φ90 53 (5.4 / 39)
Clutch Booster - Bracket φ70 26 (2.7 / 20)
(installation nut) φ90 42 (4.3 / 31)
MFW75ESH000501
5. Adjust the length of the push rod.

• Refer to "Clutch System" in this section.
Number of reversing turns of the clutch booster push

rod
Clutch 14, 15 inch
Assembly Standard 2 1/4 - 2 3/4
MFW45ESH008901
2. Apply grease to the clevis pin and assemble it to

the clutch shaft lever.
BESCO L-2, L-3 grease or equivalent

5E-40 Clutch (MZW)

• After adjusting, check to make sure that the Air leakage
amount of play in the clutch pedal is within After increasing air pressure to greater than 0.59MPa
specifications. (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 MFW45ESH009401
1. Lock nut
2. Push rod Oil leakage
Depress the clutch pedal and inspect the pipe
connections and clutch booster body for oil leakages.
Inspection Depress the clutch pedal to a certain extent, hold it in
this position, and feel if there are any changes in the
On vehicle test
pedal force over time.
• Install the clutch booster to the vehicle and after If there are no abnormalities, the piston cup gasket and
removing air from pipes and adjusting the length of oil seals can be judged to be working properly.
the push rod, perform the following inspections
and tests.
- Air leakage
- Oil leakage
- Operational test
MFW45ESH009501
Clutch (MZW) 5E-41

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
5E-42 Clutch (MZW)

Clutch size 14 inch 15 inch

Engine type 6HK1-TCN, 6HK1-TCC,
4HK1-TCS
6HF1-TCN
Power piston diameter × stroke (mm (in)) φ70 (2.76) × 35.8 (1.41) φ90 (3.54) × 35.8 (1.41)
Hydraulic piston diameter (mm (in)) φ19.80 (0.7795) φ19.80 (0.7795)
Push rod diameter (mm (in)) φ8 (0.31) φ8 (0.31)
Relay piston section diameter (mm (in)) φ16 (0.6299) × 3.6 (0.142) φ16 (0.6299) × 3.6 (0.142)
Valve piston section diameter (mm (in)) φ20.0 (0.787) φ23.5 (0.925)
mm (in)
Nominal Assembly
Limit for use Remarks
dimension standard
Relay piston diameter φ16.00 φ15.93
— —
(0.6299) (0.6271)
Gap between Relay piston section 0.04 - 0.09
— 0.11 (0.0043) —
relay piston and (φ16 (0.6299)) (0.0016 - 0.0035)
cylinder body
(φ23.5 0.1 - 0.25
— 0.3 (0.1181) —
Valve piston (0.925)) (0.0040 - 0.0098)
section (φ20.0 0.1 - 0.25
— 0.3 (0.1181) —
(0.787)) (0.0040 - 0.0098)
Hydraulic piston Power piston φ70 (2.76) φ19.80 φ19.76
— —
diameter (0.7795) (0.7780)
Power piston φ90 (3.54) φ19.80 φ19.76
— —
(0.7795) (0.7780)
Gap between hydraulic piston and hydraulic 0.01 - 0.06
— 0.08 (0.0031) —
cylinder (0.0004 - 0.0023)
Power piston Free length Power piston
— 86.8 (3.417) — —
return spring φ70 (2.76)
Power piston
— 86.8 (3.417) — —
φ90 (3.54)
Installed Power piston Compressed
62.8
load φ70 (2.76) — — length 59.9
(6.4 / 14.1)
N (kg / lb) (2.358)
Power piston Compressed
62.8
φ90 (3.54) — — length 59.9
(6.4 / 14.1)
(2.358)
Clutch (MZW) 5E-43
mm (in)
Nominal Assembly
Limit for use Remarks
dimension standard
Relay valve Free length Power piston
— 28.2 (1.110) — —
spring φ70 (2.76)
Power piston
— 22.8 (0.898) — —
φ90 (3.54)
Installed Power piston Compressed
load φ70 (2.76) — — 9.8 (1.0 / 2.2) length 13.1
N (kg / lb) (0.516)
Power piston Compressed
23.5 (2.4 /
φ90 (3.54) — — length 13.1
5.3)
(0.516)
Poppet valve Free length — 22.1 (0.870) — —
spring
Installed load N (kg / oz) Compressed
2.3 (0.23 /
— — length 13
8.1)
(0.512)
5E-44 Clutch (MZW)

d
e
b
c
MFW75ELF000401
Legend
(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) (c) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(2 caulking positions) (d) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(b) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) (e) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(power piston diameter φ70 (2.76)) (f) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) (g) 5 N⋅m (0.5 kg⋅m / 43 lb⋅in)
(power piston diameter φ90 (3.54))
Side Power Take-Off (MZW) 5G1-1
Side Power Take-Off
(MZW)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5G1-7
List of Tightening Torques . . . . . . . . . . . . . . . 5G1-11
5G1-2 Side Power Take-Off (MZW)
Air Control Type PTO

1 2 3
A-A
MFW95GLF000101
Legend
1. Air Cylinder 6. Idle Gear
2. Shift Arm 7. Idle Shaft
3. Shift Rod 8. Output Gear
4. Input Gear 9. Output Shaft
5. Input Shaft

List of Failures
PTO
Condition Possible Cause Correction

Abnormal noise from the PTO Wear and damage of the bearing of Replace the bearing
each gear
Gear engagement failure in the PTO Wear and damage on the O-ring of the Replace the O-ring
air cylinder
Wear on the tip of the sleeve and gear Replace the gear
Gear disengagement failure in the PTO Chips and tears in the return spring Replace the return spring
Damage on the tip of the sleeve and Replace the gear
gear
Oil leakage in the PTO Abnormalities in the seal on each seal Repair the liquid gasket
cover installation surface
Abnormalities in the seal on the air Repair the liquid gasket
cylinder installation surface
Abnormalities in the oil seal for the Replace the oil seal or the output shaft
output shaft, or wear on the seal contact
surface of the output shaft
Item Specification
Allowable maximum output torque 245 N⋅m (25.0 kg⋅m / 181 lb⋅ft) / 1500 r/min
Speed increasing ratio (revolution ratio against the engine) 0.78
Rotational direction (When seen from the rear side of PTO) Right rotation (clockwise)

Components
7
6
3
5
4
12
3 8
2
9
1
11
29
28
10 27
20 26
9
19 25
8
18 24
17 3
23
16
30
15 22
14 31
13 21 32
33
3
8
MFW95GLF000501
Legend
1. Shim 18. Distance Collar
2. Thrust Collar 19. Shift Arm
3. Bearing 20. Spring Pin
4. Input Gear 21. Output Shaft
5. Snap Ring 22. Key
6. Input Shaft 23. Output Gear
7. Spring Pin 24. Shim
8. Cover 25. Seal Cover
9. Bearing 26. Oil Seal
10. Idle Shaft 27. Washer
11. Idle Gear 28. Spring Washer
12. Clip 29. Nut
13. Air Cylinder 30. Case
14. Dowel Pin 31. Plug
15. O-ring 32. Shift Plug
16. Shift Rod 33. Air Connector
17. Return Spring

Disassembly 7. Remove the cover.
1. Remove the side PTO ASM from the transmission
case. 2
2. Bury the spring pin that fixes the input shaft into 1
the shaft.
3. Remove the input shaft.
• Remove the input shaft by tapping it with a
copper hammer.
• Remove the spring pin.
4. Remove the shim and thrust collar. 1
5. Remove the input gear.
6. Remove the bearing and snap ring from the input
gear.
1 MFW95GSH000401
Legend
1. Cover
2 2. Clip
8. Remove the idle shaft.

3
• Remove the idle shaft by tapping it with a
4
copper hammer.
5
3
6
7
MFW95GSH000301
Legend
1. Input shaft
2. Spring pin
3. Bearing
4. Snap ring
5. Input gear
6. Thrust collar
7. Shim
MFW95GSH000501
9. Remove the idle gear.

10. Remove the bearing.
11. Remove the air cylinder.
12. Remove the plug.
13. Remove the spring pin.
• Remove the spring pin that fixes the shift arm.
14. Remove the shift rod.
• Remove the shift rod from the shift arm.
15. Remove the shift arm.
17. Remove the return spring.
18. Remove the distance collar.

19. Remove the dowel pin.
20. Remove the air connector.
21. Remove the shift plug.
7 8
9
10 4
11
3
2
6
5
4
3
2
1 1
MFW95GSH000801
Legend
1. Cover
MFW95GSH000701 2. Shim
3. Seal cover
Legend
4. Oil seal
1. Air cylinder
2. Dowel pin
27. Remove the output shaft.
3. O-ring
4. Shift rod • Remove the output shaft to the front side by
5. Return spring tapping it with a copper hammer.
6. Distance collar 28. Remove the bearings (2 pieces).
7. Shift arm 29. Remove the output gear.
8. Spring pin
9. Plug
10. Shift plug Inspection
11. Air connector • Clean each part.
22. Remove the nut • If wear, damage, corrosion, or other abnormalities
are found on the disassembled parts, repair or
23. Remove the cover. replace the defective parts.
24. Remove the seal cover.
25. Remove the oil seal. Gear
26. Remove the shim. • Inspect whether there is any damage on the gear
tooth surface. Also, inspect the sliding surface of
the bearing for damage.
• Repair minor stepped wear and roughness on the
gear tooth surface with an oil stone or a pencil
grinder. Make replacements if there is significant
wear.

Shift arm
• Measure the thickness of the tip of the shift arm.
Thickness of the tip of the shift arm mm (in)

= 6.85 - 6.95 (0.2697 - 0.2736)
Nominal Dimension = 7 (0.28)
Limit for use = 6 (0.24)
MFW45CSH051501
Bearing
Inspect each bearing for scratches, peeling, wear, or
abnormal sounds.
• Inspect for scratches and peeling from the gap of
the roller throughout the whole circumference of
the race.
• When inspecting for wear, check whether there is
any abnormal looseness between the roller and MFW45CSH051701
the race.
• When inspecting for abnormal noise and Output shaft
smoothness of the rotation, turn the bearing by
• Inspect whether there is any wear or damages on
hand and check if there are any irregularities in
the contact surface of the output shaft to the oil
movement and abnormal sounds.
seal.
• Inspect for abnormal play in the thrust direction.
MFW75GSH008201
HCW35GSH000401
Reassembly
• Clean each mounting surface.
• Clean each part thoroughly.
• Replace the oil seal, O-ring, plug, shift plug, and
key with new ones.

• Apply gear oil, or BESCO L-2 or BESCO L-3 7. Install the seal cover.
grease or equivalent to each sliding surface, • Apply LOCTITE 5127 or equivalent to the seal
appropriately as required. cover and tighten it with bolts.
1. Set the output gear inside the case.
Tightening torque 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
2. Install the output shaft from the front side of the
8. Install the key.
case.
9. Install the dowel pin.
3. Install the bearings (2 pieces).
10. Install the distance collar.
4. Install the cover.
11. Install the return spring.
• Apply LOCTITE 5127 or equivalent to the cover
and tighten it with bolts. 12. Attach the O-ring to the shift rod.
O-ring.
5. Select an output shim(s) (1 - 4 pieces) that
13. Install the shift rod.
satisfies any of following specifications.
• While inserting the shift rod, assemble the shift
• The gap of the output bearing (thrust direction)
arm.
is 0.4 mm (0.016 in) or less
14. Install the spring pin.
• The output axis starting torque is
1.17 N⋅m (0.119 kg⋅m / 10.36 in⋅ft) or less • Fix the shift arm with the spring pin.
15. Install the plug.
Thickness of selectable shim mm (in) • Apply LOCTITE 962T or equivalent to the outer
circumference of the plug, and tap the plug until
0.10 0.15 0.20 0.40 0.65 0.80 1.00 it reaches the same surface as the case while
(0.00 (0.00 (0.00 (0.01 (0.02 (0.03 (0.03 making sure that distortion does not occur.
39) 59) 79) 57) 56) 15) 94)
16. Install the shift plug.
• Apply LOCTITE 962T or equivalent to the
6. Install the oil seal. cover, and tap it while making sure that
• Apply gear oil to the outer circumference of the distortion does not occur.
oil seal. 17. Apply LOCTITE 5127 or equivalent to the air
• Orient the lip area towards the inside, and cylinder and tighten it with bolts.
insert until it reaches the same surface as the • Apply BESCO L-2 grease or equivalent to the
surface of the seal cover while making sure that inner circumference of the cylinder.
distortion does not occur. Then, apply a thin
layer of grease (BESCO L-2 or BESCO L-3 Tightening torque 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
grease or equivalent) to the inside surface of 18. Install the air connector.
the lip area. • Apply LOCTITE 242 or equivalent to the
tapered threaded portion and install.
1 2
MFW75GSH006101
Legend
1. Seal cover
2. Oil seal
7 8 5
1 2
9
3
10
11
6
5
4
4
3
3
2 2
1
MFW95GSH000701 MFW95GSH000601
Legend Legend
1. Air cylinder 1. Idle gear
2. Dowel pin 2. Cover
3. O-ring 3. Bearing
4. Shift rod 4. Idle shaft
5. Return spring 5. Clip
6. Distance collar
7. Shift arm 23. Install the snap ring and bearings to the input gear.
8. Spring pin 24. Select input shims (2 pieces) that satisfy any of
9. Plug following specifications.
10. Shift plug
• The gap of the input bearing (thrust direction) is
11. Air connector
0.1 mm (0.004 in) or less
19. Install the idle gear. • The mobility of the input gear is
20.8 N (2.12 kg / 4.68 lb) or less (Place the
20. Install the idle shaft.
measurement part of the push-pull gauge
21. Install the bearings (2 pieces). perpendicularly to the tooth surface of the idle
22. Install the covers (2 pieces). gear, and then measure the load applied when
• Apply LOCTITE 5127 or equivalent to the cover the gear starts rotating.)
and tighten it with bolts.
Tightening torque 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) Thickness of selectable shim mm (in)
1.50 1.60 1.65 1.70 1.80 1.85
(0.059 (0.063 (0.065 (0.066 (0.070 (0.072
1) 0) 0) 9) 9) 8)
25. Install the input gear, the shims (2 pieces) selected

above, and the thrust collar to the case, and insert
the input shaft.
• If the spring pin that has been tapped in still
remains in the input shaft, remove it before
insertion.

26. Align the spring pin hole and tap in the spring pin.
3
4
5
3
6
7
MFW95GSH000301
Legend
1. Input shaft
2. Spring pin
3. Bearing
4. Snap ring
5. Input gear
6. Thrust collar
7. Shim
27. Install the washer and spring washer.

28. Install the nut.
29. Install the side PTO ASM to the transmission case.
• Apply LOCTITE 5127 or equivalent to the
installation surface.
• Apply LOCTITE 242 or equivalent to the
threaded portion of the bolt and tighten it.

b
a
MFW95GLF000801
Legend
(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) (c) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(b) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
MEMO
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MGMZW-WE-0991_62502奥付 2009.9.14 1:20 PM ページ 1
Published: Sep., 2009 All rights reserved.

Second Edition
WORKSHOP MANUAL
TRANSMISSION
(MZW model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
MGMZW-WE-0991_62502奥付 2009.9.14 1:20 PM ページ 2
2009MY
2009MY
WORKSHOP MANUAL
WORKSHOP MANUAL TRANSMISSION (MZW model)

TRANSMISSION
(MZW model)
No.MGMZW-WE-0991

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2009MY

WORKSHOP MANUAL TRANSMISSION (MZW model)

Manual Transmission (MZW) 5C-1

5C-2 Manual Transmission (MZW)

Manual Transmission (MZW) 5C-3

MZW type transmission Gear shaft (oil pump)

5C-4 Manual Transmission (MZW)

Manual Transmission (MZW) 5C-5

Condition Possible Cause Correction

5C-6 Manual Transmission (MZW)

Oil capacity [Reference value] L (US gal. / lmp gal.)

5. Tighten the filler plug at the specified torque.

Manual Transmission (MZW) 5C-7

5C-8 Manual Transmission (MZW)

Illustration Tool Number/ Description Illustration Tool Number/ Description

Manual Transmission (MZW) 5C-9

Shift Lever ASM

5C-10 Manual Transmission (MZW)

Manual Transmission (MZW) 5C-11

5 8. Assemble the shift and the outer cable of the

5. Mount the shift lever ASM to the cab.

5C-12 Manual Transmission (MZW)

Gear Control Cable

Transmission side (4H engine) Installation

2. Install the select cable (cab side).

Manual Transmission (MZW) 5C-13

Installed length of the select cable

5C-14 Manual Transmission (MZW)

6. Install the select cable (transmission side).

Manual Transmission (MZW) 5C-15

5C-16 Manual Transmission (MZW)

Vehicle Speed Sensor

3. Remove the vehicle speed sensor.

Manual Transmission (MZW) 5C-17

• The switch is judged to be normal if there is Legend

5C-18 Manual Transmission (MZW)

Backup Light Switch

• Replace the harness, connector, and seal if they Legend

Operation stroke of the switch

Manual Transmission (MZW) 5C-19

• Lift up the vehicle using a lifter.

5C-20 Manual Transmission (MZW)

3. Install the rear engine mounting to the cross

Manual Transmission (MZW) 5C-21

5C-22 Manual Transmission (MZW)

Manual Transmission (MZW) 5C-23

1. Disconnect the connector of sensor from the

8. Fully raise the crimped section (2 positions) of the

5C-24 Manual Transmission (MZW)

28. Remove the 5th dog clutch.

35. Disassemble the 5th-6th synchronizer ASM.

Manual Transmission (MZW) 5C-25

36. Remove the 6th gear and 6th block ring.

39. Remove the front case.

5C-26 Manual Transmission (MZW)

45. Remove the counter shaft ASM, input shaft ASM,

46. Remove the pin, reverse idle gear, reverse idle