ISUZU TF SERIES 2004 Workshop Manual

MANUAL TRANSMISSION 7B1-7

Transmission (4





2)
Disassembled View


RTW47BLF000701
Legend

(1) Gear Control Lever Knob (10) Slave Cylinder
(2) Rear Floor Console (bucket seat) (11) Nut : rear mount to Crossmember
(3) Front Floor Console (12) Transmission Crossmember
(4) Grommet Assembly (13) Nut : rear mount to transmission
(5) Gear Control Lever (14) Rear Mount Rubber
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe (6VE1 only) (17) Transmission Assembly
(9) Fuel Pipe Bracket

7B1-8 MANUAL TRANSMISSION

Removal
1. Disconnect battery ground cable.
2. Remove gear control lever knob (1).
3. Remove rear floor console (2). (Bucket seat)
Refer to the section “Floor Console”.
4. Remove front floor console (3).
Refer to the section “Floor Console”.
745R300006

Legend
(1) Knob
(2) Rear Floor Console
(3) Front Floor Console

5. Remove grommet assembly (4).



RTW47BMH000101

MANUAL TRANSMISSION 7B1-9

6. Remove gear control lever (5).
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.

401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)
150R300003

10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the
transmission.

Neutral Switch


Back up Switch

Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly

7B1-10 MANUAL TRANSMISSION




6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it.
Diesel engine
220LV019
6VE1
206RW002
14. Support transmission with a transmission jack.
220RS001
15. Remove engine rear mount nuts (11) fixing on cross
member from transmission crossmember (12).
16. Remove engine rear mount nuts (13) fixing on
transmission.
220R300029

Legend
(1) Transmission
(2) Nut : rear mount to transmission
(3) Rear Mount Rubber
(4) Nut : rear mount to crossmember
(5) Transmission Crossmember

MANUAL TRANSMISSION 7B1-11

17. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.
501R300008
18. Take out the rear mount rubber (14).
19. Remove starter (15) (Diesel engine only).
060L100070
20. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.

7B1-12 MANUAL TRANSMISSION

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
21. Remove transmission retaining nuts and bolts(16).
Remove transmission assembly (17) 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 spline with the clutch driven
plate spline.

MANUAL TRANSMISSION 7B1-13

4. Install the transmission assembly (17) to the engine.
Tighten the transmission nuts and bolts (16) as
shown in the figure.


Diesel engine
RTW37BLF000901

7B1-14 MANUAL TRANSMISSION

6VE1
RTW37BLF0001

MANUAL TRANSMISSION 7B1-15

C24NE
RTW37BLF0002
220RS006
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.

7B1-16 MANUAL TRANSMISSION

6. Install starter(15). (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
Remove the transmission jack from transmission
side.
10. Apply grease to top hole portion of the shift fork.
Install slave cylinder (10) and tighten the bolts to the
specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N




m (7.7 kg




m/56 lb




ft)
Nut 37 N





m (3.8 kg





m/28 lb





ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly




6VE1, C24NE
Scan-1
12. Connect transmission harness connectors and clip.
Connector: neutral switch, car speed sensor, and
backup switch.
13. Tighten exhaust pipe fixing nuts (7) to the specified
torque. (Diesel engine only)
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
150R300003