MYY &MZZ Manual Transmission -1-

MYY & MZZ MANUAL TRANSMISSION

Applicable model
Model year Vehicle model Main market
2003 or later N series All
 MYY &MZZ Manual Transmission -2-

TABLE OF CONTENTS
TRANSMISSION MECHANICAL FEATURES 3
-------------------------------------------------------------
MAIN FEATURES 4
----------------------------------------------------------------------------------------
TRANSMISSION GEAR RATIO --------------------------------------------------------------------- 5
POWER TAKE-OFF (PTO) CONTER GEAR SPECIFICATIONS -------------------------- 6
PTO INSTALLATION SURFACE -------------------------------------------------------------------- 6
CONSTRUCTIONS PARTS 7
------------------------------------------------------------------------------------
TRANSMISSION CASE (MYY 5 SPEED) 7
---------------------------------------------------------
TRANSMISSION CASE (MYY 6 SPEED) 8
---------------------------------------------------------
TRANSMISSION CASE (MZZ) 9
-----------------------------------------------------------------------
TOP GEAR SHAFT (MYY & MZZ) ------------------------------------------------------------------ 10
MAIN SHAFT (MYY 5 SPEED) 11
-----------------------------------------------------------------------
MAIN SHAFT (MYY 6 SPEED) 12
-----------------------------------------------------------------------
MAIN SHAFT (MZZ) 13
-------------------------------------------------------------------------------------
COUNTER SHAFT (MYY) 14
-----------------------------------------------------------------------------
COUNTER SHAFT (MZZ) ----------------------------------------------------------------------------- 14
CONTROL BOX ------------------------------------------------------------------------------------------ 16
GEAR SELECT & SHIFT CONTROL 17
---------------------------------------------------------------
INDEX-BALL TYPE SYNCHRONIZER ------------------------------------------------------------ 19
DETENT ASSEMBLY 20
-----------------------------------------------------------------------------------
SPEEDOMETER DRIVEN GEAR 20
-------------------------------------------------------------------
TRANSMISSION POWER FLOW ---------------------------------------------------------------------------- 21
SERVICING 27
---------------------------------------------------------------------------------------------------------
PROBLEMS & CORRECTIONS --------------------------------------------------------------------- 27
INSPECTIONS 28
--------------------------------------------------------------------------------------------
 MYY &MZZ Manual Transmission -3-

TRANSMISSION MECHANICAL FEATURES

The MYY and the MZZ model manual transmissions replace the
MXA and the MBP model from 2003 model year vehicle. By
1
changing of constructions, transmission weight is reduced and
maximum allowable input torque is increased.
The MYY model mainly employed to the 4J series engine that is
mounted NHR, NKR or some NPR tracks. And, it has also
employed to 4H series engine with low output that is mounted NKR
or NPR trucks.
The MZZ model mainly employed to 4H series engine with high
output that is mounted NPR or NQR trucks.
Both type of transmission has very similar features, and
2
construction & operation are nearly same. The service procedures
such as overhaul repair will be understood by disassembly either
the MYY or MZZ .

1. MYY 5 speed
2. MYY 6 speed
3. MZZ
 MYY &MZZ Manual Transmission -4-

MAIN FEATURES

4 1, 2, 3 4

6, 7 6, 7

12
12

11
11
5
5

Transmission Case:
1. Tube type three pieces transmission case made from cast aluminum alloy.
2. Fine pitch fixing bolts are applied for transmission case fixing.
3. Liquid type gasket is applied for sealing.
Gear, Bearing & Synchronizer:
4. Roller bearings are adopted to support the both ends of the main-shaft.
5. Tapered roller bearings are adopted to support the both ends of the counter-
shaft.
6. Common boss size at 1st, 2nd, 3rd and reverse main gear.
7. Common needle bearings are adopted at 1st, 2nd, 3rd and reverse main gear.
8. Sintered clutch hubs are adopted for all gears.
9. Common sleeves & hubs are adopted at 1st-reverse and 2nd-3rd.
10.Common sleeves are adopted at 4th-5th and 6th.
11.Index-ball type triple cone synchronizer is adopted at 1st and 2nd-3rd.
12.Index-ball type single cone synchronizer is adopted at reverse.
Shift Control:
13.Twin-rod type shift control is adopted.
14.Cast aluminum alloy shift arms are adopted at 1st-reverse, 2nd-3rd and 4th-
5th.
 MYY &MZZ Manual Transmission -5-

TRANSMISSION GEAR RATIO

Model MYY5A MYY5D MYY5M MYY5R MYY5S MYY5T

Primary (45/28) (47/26) (45/28) (45/28) (47/26) (45/28)

1st 5.315 (43/13) 5.979 (43/13) 5.315 (43/13) 5.315 (43/13) 5.979 (43/13) 5.315 (43/13)

2nd 2.908 (38/21) 3.434 (38/20) 2.908 (38/21) 2.908 (38/21) 3.434 (38/20) 3.053 (38/20)

3rd 1.558 (32/33) 1.862 (34/33) 1.655 (34/33) 1.655 (34/33) 1.752 (32/33) 1.655 (34/33)
4th 1.000 (direct) 1.297 (28/39) 1.000 (direct) 1.000 (direct) 1.000 (direct) 1.000 (direct)

5th 0.721 (22/49) 1.000 (direct) 0.721 (22/49) 0.721 (22/49) 0.795 (22/50) 0.721 (22/49)

Reverse 5.068 (41/25/13) 5.701 (41/25/13) 5.068 (41/25/13) 5.701 (41/25/13) 5.701 (41/25/13) 5.068 (41/25/13)

Model MYY6M MYY6P MYY6S

Primary (47/26) (47/26) (47/26)

1st 5.976 (43/13) 5.979 (43/13) 5.979 (43/13)

2nd 3.434 (38/20) 3.434 (38/20) 3.434 (38/20)

3rd 1.752 (32/33) 1.862 (34/33) 1.862 (34/33)

4th 1.297 (28/39) 1.297 (28/39) 1.297 (28/39)

5th 1.000 (direct) 1.000 (direct) 1.000 (direct)

6th 0.759 (21/50) 0.774 (21/49) 0.759 (21/50)

Reverse 5.701 (41/25/13) 5.701 (41/25/13) 5.701 (41/25/13)

Model MZZ6F MZZ6R MZZ6S MZZ6U

Primary (46/25) (46/25) (46/25) (46/25)

1st 6.369 (45/13) 6.369 (45/13) 6.369 (45/13) 6.369 (45/13)

2nd 3.767 (43/21) 3.767 (43/21) 3.767 (43/21) 3.767 (43/21)

3rd 1.966 (31/29) 2.234 (34/28) 2.385 (35/27) 2.234 (34/28)

4th 1.355 (28/38) 1.355 (28/38) 1.355 (28/38) 1.442 (29/37)

5th 1.000 (direct) 1.000 (direct) 1.000 (direct) 1.000 (direct)

6th 0.728 (20/47) 0.743 (19/47) 0.782 (20/47) 0.782 (20/47)

Reverse 6.369 (45/26/13) 6.369 (45/26/13) 6.369 (45/26/13) 6.369 (45/26/13)

 MYY &MZZ Manual Transmission -6-

POWER TAKE-OFF (PTO) CONTER GEAR SPECIFICATIONS

Model MYY5A/ 5S/ 6M MYY5D/ 5M/ 5R/ 5T/ 6P/ 6S MZZ6F/ 6R/ 6S MZZ6U

PTO output gear 3rd counter gear 3rd counter gear 4th counter gear 4th counter gear

Module 2.85 2.77 3.00 3.00

Pressure angle 20 ゜ 20 ゜ 20 ゜ 20 ゜

Number of teeth 33 33 38 37

Addendum modification
+0.039 +0.072 +0.074 +0.073
coefficient
Tooth depth 7.9225 7.828 8.3715 8.375

Diameter 107.9 ±0.1 105 ±0.1 134.4 131.1

Helix angle 20 ゜ 20 ゜ 25 ゜ 25 ゜

Direction Right-hand Right-hand Right-hand Right-hand

PTO INSTALLATION SURFACE

128.0
MYY model MZZ model
70.0
124.0

117.4

6.5
69.9 80.0
11.0
29.8
28.8

14.0
92.0 16.0

82.4

139.7
158.8
186.0
210.0
104.8
3rd counter gear 4th counter gear
152.0
 MYY &MZZ Manual Transmission -7-

CONSTRUCTION PARTS
TRANSMISSION CASE (MYY 5 SPEED)
3
1 2

4 5

1. Clutch housing
7
8 2. Shift rod bush
6 3. 4th-5th relay lever
9 4. 4th-5th shift block assembly
5. Control box
10 6. Interlock plate
30 29 28
7. Reverse gear switch
11 8. Detent assembly
27
12 9. Oil filler plug
26 10. Detent assembly
11. Oil drain plug
25
12. Snap ring
13
24 13. Collar
14 14. Speedometer drive gear
23 15. Main shaft end lock nut (4WD)
15 16. Reverse idle gear shaft
32 20
19 17. Reverse idle gear & needle bearing
22 18
18. Retaining plate
21 19. Counter shaft shim
31
20. Counter shaft rear bearing outer race
17
21. Detent assembly
16
22. Reverse idle gear cover
23. PTO cover
24. Dummy plug
25. Main case
33 26. Detent assembly
27. 1st-Reverse, 2nd-3rd & 4th-5th shift arm assembly
28. Front oil seal
29. Counter shaft front bearing outer race
34 30. Magnet
31. Speedometer driven gear
32. Rear cover
33. Rear oil seal
34. Parking brake assembly
 MYY &MZZ Manual Transmission -8-

TRANSMISSION CASE (MYY 6 SPEED)

1 2

3
4 1. Clutch housing
2. Shift rod bush
3. 4th-5th & 6th shift arm assembly
4. Control box
5. Interlock plate
6. Reverse gear switch
6 7 7. Detent assembly
5 8. Oil filler plug
9. Detent assembly
8 10
34 33 32 10. Spring pin
9 12 11. Oil drain plug
31 12. 6th gear relay lever
11 13. Snap ring
14. 6th shift arm & shift rod
13 15. Speedometer drive gear
30
14 16. Collar
29 17. Snap ring
18. 6th gear clutch hub assembly & sleeve
28 19. 6th gear & needle bearing
15 20. Reverse idle gear shaft
27 16 21. Reverse idle gear & needle bearing
36 24
23 22. Retaining plate
26 22 23. Counter shaft shim
38 24. Counter shaft rear bearing outer race
35 39 25 25. Detent assembly
21 26. Reverse idle gear cover
20 27. PTO cover
28. Dummy plug
19 29. Main case
30. Detent assembly
31. 1st-Reverse & 2nd-3rd shift arm assembly
18
37 32. Front oil seal
17
33. Counter shaft front bearing outer race
34. Magnet
35. Speedometer driven gear
40 36. Rear cover
37. Oil drain plug
38. Main shaft end needle bearing
39. Rear oil seal
40. Parking brake assembly
 MYY &MZZ Manual Transmission -9-

TRANSMISSION CASE (MZZ)

1 2

3
4
1. Clutch housing
2. Shift rod bush
3. 4th-5th & 6th shift arm assembly
4. Control box
5. Interlock plate
6 7 6. Reverse gear switch
7. Detent assembly
5
8. Oil filler plug
8
32 31 30 9. Detent assembly
9 10 10. Spring pin
11
29 11. 6th gear relay lever
12. Snap ring
13. 6th shift arm & shift rod
12 14. Speedometer drive gear
28 13 15. Snap ring
27 16. 6th gear clutch hub assembly & sleeve
17. 6th gear & needle bearing
18. Reverse idle gear shaft
26 19. Reverse idle gear & needle bearing
14
20. Retaining plate
25 22
21. Counter shaft shim
34 38 24 21 22. Counter shaft rear bearing outer race
23 20
23. Detent assembly
33 36 24. Reverse idle gear cover
37 19 25. PTO cover
18 26. Dummy plug
27. Main case
17 28. Detent assembly
29. 1st-Reverse & 2nd-3rd shift arm assembly
30. Front oil seal
16
31. Counter shaft front bearing outer race
35 15
32. Magnet
33. Speedometer driven gear
34. Rear cover
39 35. Oil drain plug
36. Main shaft end needle bearing
37. Rear oil seal
38. Parking brake cable bracket
39. Parking brake assembly
 MYY &MZZ Manual Transmission -10-

TOP GEAR SHAFT (MYY & MZZ)

4 1. Snap ring
2. Roller bearing
3. Top gear shaft
4. Needle bearing
5 5. Block ring
 MYY &MZZ Manual Transmission -11-

MAIN SHAFT (MYY 5 SPEED)

1
2

3
4

10
5
6 1. Snap ring
11 2. 4th-5th gear hub & sleeve
7
12 3. 5th gear block ring
8
9 4. 5th gear
13
5. 5th gear needle bearing
6. Snap ring
7. Collar
8. 3rd gear needle bearing
14 9. 3rd gear
15
10. 3rd gear inner ring
19 16 11. 3rd gear outer ring
12. 3rd gear block ring
17 13. 2nd-3rd gear hub & sleeve
14. 2nd gear block ring
15. 2nd gear outer ring
20 18 16. 2nd gear inner ring
21 17. 2nd gear
25
18. 2nd gear needle bearing
22
19. Main shaft
26 23 20. 1st gear needle bearing
21. 1st gear
24
27 22. 1st gear inner ring
23. 1st gear outer ring
24. 1st gear block ring
28
25. 1st-Reverse gear hub & sleeve
29 26. Reverse gear block ring
30 27. Reverse gear
31 28. Reverse gar needle bearing
29. Collar
30. Spacer
31. Bearing
 MYY &MZZ Manual Transmission -12-

MAIN SHAFT (MYY 6 SPEED)

1
2

3
4
1. Snap ring
10 2. 4th-5th gear hub & sleeve
5
6 3. 4th gear block ring
11 4. 4th gear
7
12 5. 4th gear needle bearing
8
13 9 6. Snap ring
7. Collar
8. 3rd gear needle bearing
9. 3rd gear
14 10. 3rd gear inner ring
15 11. 3rd gear outer ring
19 16 12. 3rd gear block ring
13. 2nd-3rd gear hub & sleeve
17 14. 2nd gear block ring
15. 2nd gear outer ring
16. 2nd gear inner ring
25
18 17. 2nd gear
20 21
18. 2nd gear needle bearing

19. Main shaft

26 22 20. 1st gear needle bearing
27 23 21. 1st gear
22. 1st gear inner ring
28 24 23. 1st gear outer ring
24. 1st gear block ring
29
25. 1st-Reverse gear hub & sleeve
26. Reverse gear block ring
30
27. Reverse gear outer ring
31 28. Reverse gear inner ring
32 29. Reverse gear
33 30. Reverse gar needle bearing
34 31. Collar
32. Spacer
33. Bearing
34. 6th gear
 MYY &MZZ Manual Transmission -13-

MAIN SHAFT (MZZ SPEED)

1 2

3
4 1. Snap ring
2. 4th-5th gear hub & sleeve
5 3. 4th gear block ring
10
6 4. 4th gear
7 5. 4th gear needle bearing
11
8 6. Snap ring
12 9
7. Collar
13
8. 3rd gear needle bearing
9. 3rd gear

10. 3rd gear inner ring

14 11. 3rd gear outer ring
15 12. 3rd gear block ring
13. 2nd-3rd gear hub & sleeve
16 14. 2nd gear block ring
15. 2nd gear outer ring
17
16. 2nd gear inner ring
25
17. 2nd gear
19 18 18. 2nd gear needle bearing

19. Main shaft

26 20. 1st gear needle bearing
21. 1st gear
27 22. 1st gear inner ring
20
21 23. 1st gear outer ring
28
24. 1st gear block ring
29 22
25. 1st-Reverse gear hub & sleeve
23
26. Reverse gear block ring
30 24 27. Reverse gear outer ring
31 28. Reverse gear inner ring
32 29. Reverse gear
33 30. Reverse gar needle bearing
34 31. Collar
32. Spacer
33. Bearing
34. 6th gear
 MYY &MZZ Manual Transmission -14-

COUNTER SHAFT (MYY)

1 2
1 2 3 6 speed 1. Snap ring
3 5 speed
4 2. Tapered roller bearing
4 5 3. Snap ring
5
6 4. Anti-lash plate
6
5. Coil spring
7 6. Straight pin
7
7. Counter shaft assembly
8. Tapered roller bearing
9. Thrust washer
10. Collar

8 8
9
10

COUNTER SHAFT (MZZ)

1 2
1. Snap ring
3 2. Tapered roller bearing
3. Counter shaft assembly
4. Tapered roller bearing
5. Thrust washer
6. Collar

6
 MYY &MZZ Manual Transmission -15-

2 3 4 5
6 7 8 9
Primary-5th counter gear and 2nd-3rd counter gear are pr
1
ess fitted to the spline.
The anti-lash plate is attached to the front part of primary
gear for MYY model.
The counter shaft is supported in the transmission case a
nd flywheel housing by tapered roller bearings at both en
ds.

10

1. Tapered roller bearing 5. 3rd counter gear 9. Tapered roller bearing

2. Anti-lash plate 6. 2nd counter gear 10. Press fitted
3. Primary gear 7. 1st counter gear
4. 5th counter gear 8. Reverse counter gear

By adopting the tapered roller bearing, the play of thrust

direction is adjusted by shim selection method. The shim
(1) adjusts clearance between bearing outer race (2) and
retaining plate (3).
The MYY model, nineteen adjusting shims are available
1
from 2.11 mm (0.083 in) to 3.19 mm (0.126 in) at interval
2 0.06 mm (0.002 in).
The MZZ model, fourteen adjusting shims are available
3
from 1.20 mm (0.047 in) to 1.98 mm (0.078 in) at interval
0.06 mm (0.002 in).

1. Shim
2. Bearing outer race
3. Retaining plate
 MYY &MZZ Manual Transmission -16-

CONTROL BOX

19
2
3
4
5

6
18 7

17

16
1. Shift lever shaft
2. Shift lever shaft oil seal
8 3. Spring
4. Washer
5. Shift internal lever
9
6. Spring seat
7. Spring
8. Pipe
10 9. Control box
10. Detent
15 11. Select internal lever
12. Select internal lever spring pin
11 13. Stopper ring
14. Stopper ring spring pin
15. Shift lever shaft spring pin
16. Neutral switch
14 13 12
17. Select lever shaft oil seal
18. Washer
19. Select external lever
 MYY &MZZ Manual Transmission -17-

GEAR SELECT & SHIFT CONTROL

1. Select lever
2. Shift lever Twin-rod shift control type is adopted for gear shift
3. Interlock plate (move to select direction)
4. 4th-5th main shift block (fixed to the rod) control. By adoption of twin-rod shift control type,
4 5. 4th-5th sub shift block (fixed to the rod)
6. 4th-5th relay lever
interlock plate (3) has attached to prevent "double
10 7. 4th-5th shift rod engagement". The section view (3) of interlock plate is
8. 4th-5th shift arm (move on the rod)
9. 1st-Reverse shift block (fixed to the rod) "T" shaped type. The lower projection fits to shift block.
10. 2nd-3rd shift arm (move on the rod) According to select lever (1) operation, it moves in hollow
11. 2nd-3rd detent groove
15 12. 1st-Reverse shift arm (fixed to the rod) of the shift block and prevents shift block movement other
13. 1st-Reverse detent groove
than selected gear.
14. 1st-Reverse & 2nd-3rd shift rod
16 15. 4th-5th main shift block turn protection pin
16. 4th-5th main shift block turn protection pin slot
MYY 5 Speed
1
• The 4th-5th main shift block (4) and 4th-5th sub block
(5) are fixed at 4th-5th shift rod (7). When shifting to
2 4th or 5th, both shift blocks are moved and then 4th-
7
14 5th shift arm (8) is moved by meaning of 4th-5th relay
3
lever (6) movement.
• The 1st-Reverse shift block (9) and 1st-Reverse shift
13 arm (12) are fixed at 1st-Reverse & 2nd-3rd shift rod
4 (14). When shifting to 1st or reverse, moved at the
same time.
5
• The 2nd-3rd shift arm (10) is one with shift block.
11
6 When shifting to 2nd or 3rd, it moves on the 1st-
12
9 Reverse & 2nd-3rd shift rod (14).

10

8
 MYY &MZZ Manual Transmission -18-

1. Select lever MYY 6 Speed & MZZ

2. Shift lever
3. Interlock plate (move to select direction) • The 6th shift block (4) is fixed at 4th-5th & 6th shift rod
4. 6th shift block (fixed to the rod)
4 5. 4th-5th detent groove (8). When shifting to 6th, 4th-5th & 6th shift rod (8) is
6. 4th-5th shift arm (move on the rod) moved and then 6th shift arm (16) moved by meaning
7. 6th detent groove
8. 4th-5th& 6th shift rod of 6th relay lever movement (15).
9. 1st-Reverse & 2nd-3rd shift rod
10. 1st-Reverse shift block (fixed to the rod) • 1st-Reverse shift block (10) and 1st-Reverse shift arm
11. 2nd-3rd shift arm (move on the rod) (13) are fixed at 1st-Reverse & 2nd-3rd shift rod (9).
18
12. 2nd-3rd detent groove
19 13. 1st-Reverse shift arm (fixed to the rod) When shifting to 1st or reverse, moved at the same
6 14. 1st-Reverse detent groove
15. 6th relay lever
time.
16. 6th shift arm (fixed to the rod) • 2nd-3rd shift arm (11) is one with shift block. When
17. 6th sub shift rod
1
18. 6th shift block turn protection pin shifting to 2nd or 3rd, it moves on the 1st-Reverse &
19. 6th shift block turn protection pin slot
2nd-3rd shift rod (9).
2
• 4th-5th shift arm (6) is one with shift block. When
8
shifting to 4th or 5th, it moves on the 4th-5th & 6th shift
7 15
rod (8).
3 14

5
17
12

10 13
9 16

11

6
 MYY &MZZ Manual Transmission -19-

INDEX-BALL TYPE SYNCHRONIZER

1 2 3 Index Synchronization Gear selected

5 4

1. Index-ball
2. Index-spring
3. Sleeve
4. Block ring Index-ball type synchronizer is adopted at 1st, 2nd, 3rd
5. Synchronizer cone (triple cone) and reverse (single cone). In comparison
6. Outer ring
7. Inner ring 1 2 3 with insert key type, gear select controllability is improved
7 6 5 4
due to low resistance during sleeve is moving (gear is
shifting). (Insert key type generates moving resistance
between side of insert and block ring.)

Triple cone type

 MYY &MZZ Manual Transmission -20-

DETENT ASSEMBLY
View A
In order to improve serviceability, detent spring and ball
are assembled as one parts.

1 2 3
1. Ball
2. Ball seat
3. Spring

SPEEDOMETER DRIVEN GEAR

1 The speedometer driven gear bush uses an eccentric
2 type bush that can fit some variations of speedometer
driven gear depending on the number of tooth
(=diameter).
When installing the bush, align the mark of tooth number
to the retaining plate notch after counting the actual
3
speedometer driven gear tooth.
4
5 1. Vehicle speed sensor (VSS)
6 2. VSS drive shaft
3. Retaining plate
4. Bush
5. O-ring
6. Speedometer driven gear
 MYY &MZZ Manual Transmission -21-

TRANSMISSION POWER FLOW

MYY 5 Speed 1st MYY 5 Speed 2nd

MYY 6 Speed 1st MYY 6 Speed 2nd

 MYY &MZZ Manual Transmission -22-

MYY 5 Speed 3rd MYY 5 Speed 4th

MYY 6 Speed 3rd MYY 6 Speed 4th

 MYY &MZZ Manual Transmission -23-

MYY 5 Speed 5th

MYY 6 Speed 5th MYY 6 Speed 6th

 MYY &MZZ Manual Transmission -24-

MYY 5 Speed Reverse

MYY 6 Speed Reverse

 MYY &MZZ Manual Transmission -25-

MZZ 1st MZZ 2nd

MZZ 3rd MZZ 4th

 MYY &MZZ Manual Transmission -26-

MZZ 5th MZZ 6th

MZZ Reverse
 MYY &MZZ Manual Transmission -27-

SERVICING
PROBLEMS & CORRECTIONS
PROBLEM POSSIBLE CAUSE CORRECTION

Abnormal Noise Flywheel pilot bearing wear Replace the bearing

Main shaft or countershaft bearing wear or other damage Replace the bearing(s)

Main shaft gear, counter-shaft gear, and/or reverse idle gear wear or Replace the gear(s)
other damage

Main shaft spline and/or synchronizer hub spline wear Replace the spline(s)

Gear or bearing thrust surface scoring Replace the gear(s)and/or bearing(s)

Insufficient backlash between mating gears Replace the gears

Difficult shifting Insufficient clutch pedal play Adjust the play

Change lever contact surface wear Repair or replace the change lever and apply grease

Shift block, shift rod, and/or control box contact surface wear Replace the worn components

Shift arm and/or synchronizer sleeve wear Replace the worn parts

Thrust washer and collar and/or gear thrust surface wear (Main shaft Replace the worn parts
and counter-shaft thrust play)

Synchronizer wear Replace the synchronizer

Gear slippage Detent ball wear Replace the detente assembly

Shift rod and/or control box contact surface wear Replace the worn components

Shift arm and/or synchronizer sleeve wear Replace the worn parts

Thrust washer and collar and/or gear thrust surface wear (Main shaft Replace the worn parts
and counter-shaft thrust play)

Bearing wear or other damage Replace the worn or damaged bearings

Main shaft spline and synchronizer hub spline wear Replace the worn parts

Synchronizer spring weak or broken Replace the spring

Oil leakage Drain plug and/or filler plug loose Tighten the plug(s)

Broken gasket Replace the gasket

Oil seal wear or damage Replace the oil seal

 MYY &MZZ Manual Transmission -28-

INSPECTIONS Main Shaft Deflection

Shift Arm Thickness

Required tool: Dial gauge & V-block

Required tool: Micrometer Service standard: 0.015 mm (0.0006 in)
Service standard: 9.60 - 9.85 mm (0.378 - 0.388 in) Service limit: 0.1 mm (0.0039 in)
Service limit: 9.0 mm (0.354 in) (1st-Reverse/ 2nd-3rd / 4th-5th)
9.3 mm (0.366 in) (6th) Spline & Hub Free Play

Gear Internal Diameter

Required tool: Inside dial gauge

Service standard:
MYY
Required tool: Dial gauge
63.010 - 63.029 mm (2.4807 - 2.4815 in) (1st, 2nd, 3rd & reverse)
Service standard: 0 - 0.05 mm (0 - 0.002 in)
44.009 - 44.025 mm (1.7326 - 1.7333 in) (4th & 5th)
Service limit: 0.3 mm (0.012 in)
50.009 - 50.025 mm (1.9689 - 1.9695 in) (6th)
MZZ
63.010 - 63.029 mm (2.4807 - 2.4815 in) (1st, 2nd, 3rd & reverse) Spline & Hub Free Play
55.010 - 55.029 mm (2.1657 - 2.1665 in) (4th)
48.009 - 48.025 mm (1.8901 - 1.8907 in) (5th)
50.009 - 50.025 mm (1.9689 - 1.9695 in) (6th)
Service limit:
MYY
63.069 mm (2.4830 in) (1st, 2nd, 3rd & reverse)
44.065 mm (1.7348 in) (4th & 5th)
55.065 mm (1.9711 in) (6th)
MZZ Required tool: Feeler gauge
63.069 mm (2.4830 in) (1st, 2nd, 3rd & reverse) Service standard:
55.069 mm (2.1681 in) (4th) 1.0 - 2.5 mm (0.039 - 0.098 in) (1st, 2nd & 3rd)
48.065 mm (1.8923 in) (5th) 1.3 - 2.6 mm (0.051 - 0.102 in) (4th, 5th, 6th & reverse)
55.065 mm (1.9711 in) (6th) Service limit: 0.5 mm (0.02 in)
 MYY &MZZ Manual Transmission -29-

Insert Key & Block Ring Groove Clearance

Required tool: Venire caliper

Service standard: 3.46 - 3.76 mm (0.136 - 0.148 in) (4th, 5th & 6th)

Insert Key & Clutch Hub Clearance

Required tool: Feeler gauge

Service standard: 0.01 - 0.21 mm (0.0004 - 0.0083 in) (4th, 5th & 6th)

Block Ring & Clutch Hub

Required tool: Feeler gauge

Service standard:
MYY
4.3 - 4.7 mm (0.169 - 0.185 in) (1st, 2nd, 3rd & reverse)
MZZ
3.3 - 3.7 mm (0.130 - 0.146 in) (1st, 2nd, 3rd & reverse)
4.3 - 4.7 mm (0.169 - 0.185) (4th, 5th & 6th)
 MYY &MZZ Manual Transmission -30-

SERVICE SPECIAL TOOL (SST)

SST parts SST parts
SST illustration SST usage SST name SST illustration SST usage SST name
number number

5-8840-2750-0
Oil seal (MYY) 　 Bearing
5-8840-2244-0
installer 5-8840-2751-0 installer
(MZZ)

Bearing
Grip 5-8840-0007-0 5-8840-2757-0
remover

Bushing
Bushing
remover and 5-8840-2755-0 5-8840-2802-0
puller
installer

Remover 5-8840-0027-0 Installer 5-8840-2345-0

Sliding Bearing
5-8840-0084-0 5-8840-2587-0
hammer remover

Universal Oil seal

5-8840-2043-0 5-8840-2793-0
holder protector

5-8840-2752-0
Bearing Bearing (MYY)
5-8840-2026-0
installer installer 5-8840-2753-0
(MZZ)
 MYY &MZZ Manual Transmission -31-

SST parts
SST illustration SST usage SST name
number

Control box
oil seal 5-8840-2245-0
installer

Oil seal
5-8840-3558-0
installer

Wrench
(4WD model 5-8840-2798-0
only)
 MYY &MZZ Manual Transmission -32-

Issued by
ISUZU MOTORS LIMITED
SERVICE MARKETING DEPARTMENT
Tokyo, Japan

COPYRIGHT-ISUZU MOTORS LIMITED

SBT-TM-MYMZ-2-03 (Version 3.0)

February 2012

THE RIGHT IS RESERVED TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE