ISUZU TF SERIES 2004 Workshop Manual

MSG MODEL 7B-13





Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Torque N

m (kgf

m/lb

ft)
78 (8.0 / 58)




Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque N

m (kgf

m/lb

ft
)
78 (8.0 / 58)

Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.



Rear Propeller Shaft (Single Shaft Type)
1. Insert the splined yoke 1 with the propeller shaft into the
transmission main shaft spline
2 .
2. Install the propeller shaft flange yoke
3 to the drive pinion
side.
3. Tighten the propeller shaft flange yoke bolt to the specified
torque.
Propeller Shaft Flange Yoke Bolt Torque N
m (kgf
m/lb
ft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)



Rear Propeller Shaft (Dual Shaft Type)
1. Place the center bearing and retainer 1 together with the
1st propeller shaft
2 and 2nd propeller shaft 7 on the No.4
crossmember
3.
2. Insert the splined yoke
4into the transmission main shaft
spline
5.
3. Tighten the center bearing retainer bolts
6 to the specified
torque.
Center Bearing Retainer Bolt Torque N

m (kgf

m/lb

ft)
60.8 (6.2 / 44.8)



4. Connect the 2nd propeller shaft
7 and drive pinion side 8.
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque N

m (kgf

m/lb

ft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)

7B-14 MSG MODEL



Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the
2nd exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.

Gear Shift Lever
1. Replenish the transmission case with the specified engine
oil.
Transmission Case Oil lit(US gal.)
1.55 (0.41)

2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified
torque.
Shift Lever Cover Bolt Torque N

m(kgf

m/lb

ft)
19.6 (2.0 / 14.5)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.



Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.



Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.



Battery Cable
Connect the negative (-) cable to the battery terminal.

MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS




RTW47BLF000301

Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly


6. Front cover with oil seal



7. Counter gear snap ring


8. Bearing snap ring
9. Rear cover with oil seal
10. Transmission case
11. Intermediate plate with gear assembly

7B-16 MSG MODEL



Important Operations
6. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission
case.



7. Counter Gear Snap Ring
8. Bearing Snap Ring
Use pair of snap ring pliers to remove the snap ring.

MSG MODEL 7B-17
MAJOR COMPONENT

INTERNAL PARTS




Disassembly steps
1. Detent assembly
2. Shift fork assembly & interlock pin
3. Rev. and 5th gear assembly

4. Counter gear shaft assembly
5. Top & main gear shaft assembly

7B-18 MSG MODEL
MINOR COMPONENTS

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN


Disassembly Steps
1. Detent spring plate and gasket
2. Detent spring


3. Detent ball
4. Rev. - 5th shaft rod
5. Rev. - 5th shaft arm
6. 1st - 2nd shift rod



7. 3rd - 4th shift rod


8. 3rd - 4th shift arm


9. 1st - 2nd shift arm
10. Interlock pin
11. Intermediate plate and gear assembly

MSG MODEL 7B-19


Important Operations
3. Detent Ball




7. 3rd - 4th Shift Rod
8. 3rd - 4th Shift Arm
9. 1st - 2nd Shift Arm
1) Hold a round bar against the shift arm end.
This will prevent damage to other components.





2) Use a spring pin remover to remove the shift arm spring pin
from the shift arm and the shift rod.
Spring Pin Remover : 9-8529-2201-0
Discard the used spring pin.
3) Move the 3rd - 4th shift rod forward.
Take care not to lose the interlock pins.

7B-20 MSG MODEL
REVERSE GEAR AND 5TH GEAR


Disassembly Steps
1. Bearing snap ring
2. Speedometer drive gear and lock ball
3. Bearing spacer
4. Mainshaft end ball bearing
5. Thrust ring snap ring
6. Thrust washer thrust ring
7. Thrust washer and lock ball
8. Counter reverse gear nut and washer


9. Counter end ball bearing


10. Counter 5th gear
11. Counter reverse gear
12. 5th gear
13. 5th block ring
14. Needle bearing



15. Mainshaft lock nut and washer


16. Rev. - 5th synchronizer assembly
17. Reverse gear
18. Needle bearing
19. Needle bearing collar
20. Thrust washer
21. Counter reverse gear lock nut
22. Thrust washer
23. Reverse idler gear
24. Thrust washer
25. Reverse idler shaft


26. Bearing snap ring


27. Bearing snap ring


28. Intermediate plate

MSG MODEL 7B-21






Important Operations
9. Counter End Ball Bearing
10. Counter 5th Gear
Use the gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)




15. Mainshaft Lock Nut and Washer
1) Engage the 3rd - 4th synchronizer with the 3rd gear.
2) Engage the 1st - 2nd synchronizer with the 1st gear.
3) Attach the holding fixture to the mainshaft and the
countergear.
Holding Fixture : 5-8840-2001-0 (J-29768)




4) Use the lock nut wrench to remove the lock nut.
Lock Nut Wrench: 5-8840-0353-0 (J-36629)







16. Rev. - 5th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts






26. Bearing Snap Ring
1) Insert the snap ring pliers

1 into the counter gear bearing
snap ring hole
2.
The snap ring hole is in the intermediate plate
3.
2) Use the snap ring pliers to force open the counter gea
r
bearing snap ring.
Tap on the front of the intermediate plate.
The ball bearing snap ring will come free.

7B-22 MSG MODEL




27. Bearing Snap Ring
28. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap
ring hole.
The snap ring hole is in the intermediate plate

1.
2) Use the snap ring pliers
2to force open the mainshaft
bearing snap ring
3.
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the
transmission to remove it.
The ball bearing snap ring will come free.