clutch ISUZU TF SERIES 2004 Workshop Manual

MANUAL TRANSMISSION 7B1-69

NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064


220RW019

Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
24. Remove transmission retaining nuts and bolts(17).
Remove transmission assembly (18) from the
vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft with the clutch driven plate
spline.

7B1-72 MANUAL TRANSMISSION




RTW37BLF000201

5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.

220RS006

MANUAL TRANSMISSION 7B1-77

Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring (5)
from the transmission case.
4. Remove the shift fork, and boot. (Diesel engine,
C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)



RTW47BSH000601

Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002

Legend
(1) Fulcrum bridge
8. Remove the front cover (8) and gasket from the
transmission case.
9. Remove snap ring (7) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (9) fixing top gear bearing.

226RS001
11. Remove gear control box assembly (1).
12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).

MANUAL TRANSMISSION 7B1-89

2. Install bearing snap ring (26).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (25).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N




m (1.5 kg




m/11 lb




ft)

220RW137
4. Install needle bearing (24), reverse gear (23), and
reverse block ring (22). 5. Assemble rev-5th synchronizer assembly (21) by
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
2. Check that the inserts (3) fit snugly into the
clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (21) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.

226RS013

226RS049

MANUAL TRANSMISSION 7B1-95

Legend

(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring
(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft

7B1-96 MANUAL TRANSMISSION

Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the ball bearing(3).
226RW216
4. Remove needle bearing (4) and top block ring (5),
mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the
mainshaft snap ring (6).

226RS008

6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
Disassemble the synchronizer assembly.
226RW217

Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
8. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RW218

MANUAL TRANSMISSION 7B1-97

9.Disassemble 1st inside ring (15), 1st outside ring (16),
and 1st block ring (17).
10.Remove needle bearing (18).
11.Use a pair of snap ring pliers to remove the clutch
hub snap ring (19).

226RS031
12.Use bench press and the bearing remover 5-8840-
0015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
Disassemble the synchronizer assembly.
226RW220

Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
13. Remove needle bearing (25) from mainshaft (26).
14. Remove bearing snap ring (27).
15. Remove the front roller bearing (28) by performing
the following steps.


Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.

Remove the inner race by using a bench press
and remover 5-8840-0015-0.
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16. Remove center roller bearing (29) from counter gear
shaft (30).

MANUAL TRANSMISSION 7B1-99

1st-2nd Synchronizer (3-CONE)

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.

Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance


Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.

226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.158 in)
1st-2nd3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)

Clutch Hub and Insert Clearance


Use a thickness gauge to measure the clearance
between the clutch hub and the insert.

226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.

Clutch Hub and Insert Clearance
Standard Limit
1st-2nd
3rd-4th 0.01 – 0.21 mm
(0.004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)

MANUAL TRANSMISSION 7B1-101

Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.

226RS042


Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.

Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play


Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)




226RS043

Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).


Apply engine oil to the bearing inner and outer
circumferences.


Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.

226RS044
2. Install front roller bearing (28) by performing the
following steps.


Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).


Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.

7B1-102 MANUAL TRANSMISSION



Use bearing installer 5-8840-2194-0 to install the
ring.



226RS045

Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install bearing snap ring (27) to counter gear shaft
(30).
4. Apply engine oil to the needle bearing (25) and the
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24)
to the mainshaft (26).
The 2nd gear (24) dog teeth must be facing the
transmission rear side.

226RS046

5. Assemble 2nd inside ring (23), 2nd outside ring (22),
and 2nd block ring (21).


Apply engine oil to the synchronizer ring friction
surfaces.

226RS047

Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by
performing the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub (5) insert grooves.
2. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.