manual transmission ISUZU TF SERIES 2004 Repair Manual

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

MANUAL TRANSMISSION 7B1-17

14. Install the exhaust pipe (8). (6VE1)
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
RTW37ASH000101
15. Install rear propeller shaft (6).
Torque: 63 N




m (6.4 kg




m/46 lb




ft)
16. Install center bearing on crossemember.
Torque: 69 N




m (7.0 kg




m/51 lb




ft)
17. Install gear control lever (5).
Torque: 19 N




m (1.9 kg




m/14 lb




ft)
18. Install grommet assembly (4).
Torque: Screw 1.4 N




m (0.14 kg




m/12 lb




in)
Nut 7 N




m (0.7 kg




m/61 lb




in)




RTW47BMH000101

Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front
19. Install front floor console (3) and rear floor console
(2).
20. Install gear control lever knob (1).
To the female thread portion, adhesive (TB1344 or
LOCTITE 222 or equiv.) of 3 - 4 drops to be applied
and transmission knob tightened.
Torque: 9 N




m (0.9 kg




m/78 lb




in)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
21. Connect battery ground cable.

7B1-18 MANUAL TRANSMISSION

Transmission Case
Major Component
RTW37BLF0005
Legend

(1) Gear Control Box Assembly and Gasket (9) Front Cover (with Oil Seal)
(2) Speedometer Sensor and Driven Gear (10) Top Gear Bearing Snap Ring
(3) Rear Cover Assembly (11) Release Bearing : C24NE
(4) Intermediate Plate with Gear Assembly (12) Shift Fork : C24NE
(5) Transmission Case (13) Fulcrum Bridge : 6VE1
(6) Release Bearing (with Spring) : Diesel engine (14) Release Bearing : 6VE1
(7) Shift Fork : Diesel engine (15) Shift Fork : 6VE1
(8) Counter Front Bearing Snap Ring

MANUAL TRANSMISSION 7B1-19

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
(6)(11) from the transmission case.
4. Remove the shift fork (7)(12), 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 (9) and gasket from the
transmission case.
9. Remove snap ring (8) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (10) fixing top gear bearing.

226RS001
11. Remove the speedometer sensor (2).
Remove the plate (2).
Remove the driven gear bushing and driven gear
(2).
NOTE : Apply a reference mark to the driven gear
bushing before removal.
12. Remove gear control box assembly (1).