reverse ISUZU TF SERIES 2004 Owners Manual

7B-34 MSG MODEL
REVERSE GEAR AND 5TH GEAR



Reassembly Steps


1. Intermediate plate


2. Reverse idler shaft
3. Bearing snap ring
4. Bearing snap ring
5. Thrust washer


6. Reverse idler gear
7. Thrust washer


8. Counter reverse gear lock nut


9. Thrust washer
10. Needle bearing collar
11. Needle bearing
12. Reverse gear


13. Rev.-5th synchronizer assembly


14. Mainshaft lock nut and washer

15. Needle bearing
16. 5th block ring
17. 5th gear


18. Thrust washer and lock ball
19. Counter reverse gear
20. Counter 5th gear
21. Counter end ball bearing


22. Counter reverse gear nut and washer


23. Thrust washer thrust ring


24. Thrust ring snap ring
25. Mainshaft end ball bearing
26. Bearing spacer
27. Speedometer drive gear and lock ball
28. Bearing snap ring

MSG MODEL 7B-35


Important Operations
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque Nm(kgfm/lbft)
18.6 (1.9 / 13.7)



3) Set the mainshaft with gear assembly

1 and the counter
gear assembly

2 to the holding fixture
3.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the
counter shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the
counter gear ball bearings.



6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque Nm (kgfm/lbft)
107.8 (11 / 79.6)



9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse
gear side.

7B-36 MSG MODEL


13. Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer

1 and the insert short side
2
must be facing to the rear side of the transmission.


14. Mainshaft Lock Nut and Washer
1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use the lock nut wrench to tighten the lock nut to the
specified torque.
Lock Nut Wrench : 5-8840-0353-0 (J-36629)
Lock Nut Torque Nm(kgfm/lbft)
107.8 (11 / 79.6)



22. Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque N
m(kgf
m/lb
ft)
107.8 (11 / 79.6)



18. Thrust Washer and Lock Ball
23. Thrust Washer Thrust Ring
24. Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the
thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.


3) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.

MANUAL TRANSMISSION 7B1-1

SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (4





2)
Service Precaution .......................................................................................................... 7B1 – 3
General Description ........................................................................................................ 7B1 – 4
Rear Oil Seal (4




2) ........................................................................................................... 7B1 – 5
Transmission (4




2) ......................................................................................................... 7B1 – 7
Disassembled View ..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –12
Transmission Case .......................................................................................................... 7B1 –18
Major Component ........................................................................................................ 7B1 –18
Disassembly ................................................................................................................ 7B1 –19
Reassembly ................................................................................................................. 7B1 –20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –23
Disassembled View ..................................................................................................... 7B1 –23
Disassembly ................................................................................................................ 7B1 –24
Inspection and Repair ................................................................................................. 7B1 –25
Reassembly ................................................................................................................. 7B1 –26
Reverse Gear and 5th Gear ............................................................................................ 7B1 –27
Disassembled View ..................................................................................................... 7B1 –27
Disassembly ................................................................................................................ 7B1 –29
Inspection and Repair ................................................................................................. 7B1 –31
Reassembly ................................................................................................................. 7B1 –31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –38
Disassembled View ..................................................................................................... 7B1 –38
Disassembly ................................................................................................................ 7B1 –40
Inspection and Repair ................................................................................................. 7B1 –42
Reassembly ................................................................................................................. 7B1 –45
Main Data and Specifications ......................................................................................... 7B1 –51

7B1-2 MANUAL TRANSMISSION

Troubleshooting ............................................................................................................... 7B1 –55
Special Tools (4





2) .......................................................................................................... 7B1 –62


MUA (4





4)
Service Precaution .......................................................................................................... 7B1 –63
General Description ........................................................................................................ 7B1 –64
Transmission (4




4) ......................................................................................................... 7B1 –65
Disassembled View ..................................................................................................... 7B1 –65
Removal ....................................................................................................................... 7B1 –66
Installation ................................................................................................................... 7B1 –70
Transmission Case .......................................................................................................... 7B1 –77
Major Component ........................................................................................................ 7B1 –77
Disassembly ................................................................................................................ 7B1 –78
Reassembly ................................................................................................................. 7B1 –79
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –82
Disassembled View ..................................................................................................... 7B1 –82
Disassembly ................................................................................................................ 7B1 –83
Inspection and Repair ................................................................................................. 7B1 –83
Reassembly ................................................................................................................. 7B1 –84
Reverse Gear and 5th Gear ............................................................................................ 7B1 –85
Disassembled View ..................................................................................................... 7B1 –85
Disassembly ................................................................................................................ 7B1 –86
Inspection and Repair ................................................................................................. 7B1 –88
Reassembly ................................................................................................................. 7B1 –88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –94
Disassembled View ..................................................................................................... 7B1 –94
Disassembly ................................................................................................................ 7B1 –96
Inspection and Repair .............................................................................................. 7B1 – 98
Reassembly .............................................................................................................. 7B1 – 101
Main Data and Specifications ..................................................................................... 7B1 – 107
Troubleshooting ........................................................................................................... 7B1 – 111
Special Tools (4





4) ...................................................................................................... 7B1 – 118

MANUAL TRANSMISSION 7B1-23

Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View



RTW47BLF000501
Legend

(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly

7B1-24 MANUAL TRANSMISSION

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

220RS011
2. Remove spring (4).
3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).


Hold a round bar against the shift rod end.

230RS003


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


230RS0004

Be careful not to lose the interlock pins, when
pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.

230RS0005


Remove the rev-5th, 1st-2nd and 3rd-4th shift
rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).

7B1-26 MANUAL TRANSMISSION

Reassembly
1. Install rev-5th shift arm and reverse inhibitor (6) and
rev-5th shift rod (5).

Apply oil to the reverse inhibitor inner surface.

Install the shift rod in the intermediate plate (12).


Hold a round bar against the shift rod end lower
face to protect it against damage.

Install a new spring pin.
Never reinstall the used spring pin.


Install the interlock pin (11) in the intermediate
plate (12).
Do not allow the interlock pin to fall from the
intermediate plate (12).
2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9)
to intermediate plate and gear assembly (12).
3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).


Install the interlock pin (11) in the intermediate
plate and gear assembly (12).


Install the 3rd-4th shift rod (8) in the intermediate
plate (12).
Do not allow the interlock pin to fall from the
intermediate plate.


Install the interlock pin (11) and then 1st-2nd
shift rod (7) in the intermediate plate (12).
Do not allow the interlock pin to fall from the
intermediate plate.


Hold a round bar against the shift rod end lower
face to protect it against damage.

Install a new spring pin.
Never reinstall the used spring pin.

230RS007
4. Install spring (4).
5. Put detent balls (3) in the intermediate plate holes.


Apply oil to the detent balls.
6. Install detent springs (2) and detent spring plate and
gasket (1).


Install a new gasket and the detent spring plate.


Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb




ft)


220RS030

Legend
(1) Warped

MANUAL TRANSMISSION 7B1-27

Reverse Gear and 5th Gear
Disassembled View
226R300027

Legend

(1) Bearing Snap Ring (11) Reverse Idler Gear Assembly
(2) Ball Bearing (12) Idle Shaft Pin
(3) Bearing Snap Ring (13) Thrust Washer
(4) Speedometer Drive Gear (14) Reverse Idler Gear
(5) Clip (15) Reverse Idler Shaft
(6) Retainer Snap Ring (16) Bearing Snap Ring
(7) Retainer (17) Ball Bearing
(8) Thrust Plate (18) Counter 5th Gear
(9) Thrust Washer and Lock Ball (19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring (20) 5th Gear

7B1-28 MANUAL TRANSMISSION

(21) 5th Block Ring (26) Reverse Gear
(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate