Transmission ISUZU TF SERIES 2004 Workshop Manual

7B1-78 MANUAL TRANSMISSION

Rear Oil Seal Replacement
220R300025

Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard
the used oil seal.
2. Apply engine oil to new oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 5-
8840-0007-0 to install the oil seal to the rear case.
Reassembly
1. Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transmission case (4),
intermediate plate (3) and rear case (2) fitting
surfaces.
2. Install the intermediate plate with gear assembly (3)
to the transmission case (4).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal (2) on the
intermediate plate with gear (3) by performing the
following steps.


Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.


Tighten the transmission rear case bolts and
nuts to the specified torque.
Torque: 37 N




m (3.8 kg




m/27 lb




ft)

220R300026

Notes When Tightening the Bolt:


After cleaning the bolt hole, dry it thoroughly with air.

After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
liquid gasket (LOCTITE 242) or its equivalent on
them before tightening it.
4. Install a new gasket and gear control box assembly
(1).
Install the harness clips and brackets and then
tighten four new gear control box bolts to the
specified torque.
Torque: 20 N




m (2.0 kg




m/14 lb




ft)
261R300004

MANUAL TRANSMISSION 7B1-79

5. Install top gear bearing snap ring (9) and counter
front bearing snap ring (7).


Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.


The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal (8).
Front Cover Oil Seal Replacement


Remove the oil seal from the front cover.


Apply engine oil to a new oil seal outer
circumference.

Apply recommended grease to the oil seal lip.


Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R3000020
8. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (6).
(Diesel engine, C24NE)
F07L100026
9. Install the fulcrum bridge to the transmission case.
(6VE1)
Torque: 38 N




m (3.9 kg




m/28 lb




ft)
RTW37ASH0002

Legend
(1) Fulcrum bridge

10. Apply molybdenum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
(6VE1)
11. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)

7B1-80 MANUAL TRANSMISSION

12. Install the washer and snap pin. (6VE1)



RTW47BMH000201
13. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover,
joining it to the shift fork.

MANUAL TRANSMISSION 7B1-81

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

7B1-82 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).

MANUAL TRANSMISSION 7B1-83

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

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

Shift Arm Thickness
Standard Limit
1st-2nd 9.60 - 9.85 mm
(0.378 - 0.388 in)
3rd-4th
Rev.5th 9.60 - 9.80 mm
(0.378 - 0.386 in) 9.0 mm
(0.354 in)

230RS006
Detent Spring Free Length


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

Detent Spring Free Length
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)


SOUTH AFRICA 5th-Rev Only
Detent Spring Free Length
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in)

220RS012
Detent Spring Tension


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

Detent Spring Tension
Compressed height Standard
20 mm (0.787 in) 87.2 - 97.1 N
(19.6 - 21.8 lb)

220RS013


SOUTH AFRICA 5th-RV Only
Detent Spring Free Length
Compressed Standard
Outer 20 mm (0.787 in) 93.5 – 103.3 N
(21.0 – 23.3 lb)
Inner 20 mm (0.787 in) 26.4 – 36.3 N
(5.9 – 8.2 lb)

7B1-84 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 7B1-85

Reverse Gear and 5th Gear
Disassembled View
226R300024

Legend

(1) Collar Snap Ring (15) Counter 5th Gear
(2) Oil Seal Collar (16) Counter Reverse Gear
(3) Ball Bearing (17) 5th Gear
(4) Retainer (18) 5th Block Ring
(5) Thrust Plate (19) Needle Bearing
(6) Thrust Washer and Lock Ball (20) Mainshaft Nut
(7) Reverse Idler Gear Snap Ring (21) Rev-5th Synchronizer Assembly
(8) Reverse Idler Gear Assembly (22) Reverse Block Ring
(9) Idle Shaft Pin (23) Reverse Gear
(10) Thrust Washer (24) Needle Baring
(11) Reverse Idler Gear (25) Bearing Plate and Screw
(12) Reverse Idler Shaft (26) Bearing Snap Ring
(13) Bearing Snap Ring (27) Intermediate Plate
(14) Ball Bearing

7B1-86 MANUAL TRANSMISSION

Disassembly
1. Use a pair of snap ring pliers to remove the collar
snap ring (1).
2. Set the retaining ring remover 5-8840-2158-0 and
puller 5-8840-2027-0 to the retainer (4) and the
mainshaft end.
262RW079
3. Remove the retainer (4) together with the bearing
(3) and the oil seal collar (2).
The universal puller may be used in place of the
retaining ring remover.
4. Remove thrust plate (5) and thrust washer and lock
ball (6).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (7).

226RS004

6. Remove the reverse idler gear assembly (8) from
the intermediate plate (27).

226RS005
7. Remove idle shaft pin (9), thrust washer (10),
reverse idler gear (11), and reverse idler shaft (12).
8. Use a pair of snap ring pliers to remove the snap
ring (13).
9. Attach a universal puller to the counter gear shaft.
Use a universal puller to remove the ball bearing
(14) and the counter 5th gear (15).

226RS006
10. Remove counter reverse gear (16).

MANUAL TRANSMISSION 7B1-87

11. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).

226RS007
12. Remove the mainshaft nut (20) according to
following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
226RW212


Engage the 3rd-4th synchronizer with the 3rd
gear.


Engage the 1st-2nd synchronizer with the 1st
gear.

226RW210

Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut (20).
226RW211