oil ISUZU TF SERIES 2004 Workshop Manual

MANUAL TRANSMISSION 7B1-55

2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)Worn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)Worn, chipped, or cracked
gear(s)
NG NG NG NG OK
OK
OK OK
Gear oil (Metallic rattling)

7B1-56 MANUAL TRANSMISSION

2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OKNG NG NG NG
OK OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxWorn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG NG
OKShift block sleeve movement

7B1-60 MANUAL TRANSMISSION

4. OIL LEAKAGE

Checkpoint Trouble Cause Countermeasure

Gear oilReplace the gear oilImproper gear oil
Drain plug and/or filler plugTighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OKNG NG NG
OK OKOil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
Worn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil sealReplace the oil seal
Replace the gasket(s)
Worn or scratched oil seal
Defective or improperly
installed gasket(s)
OK
NG NG NG NG
OK OKGaskets

MANUAL TRANSMISSION 7B1-61

Special Tools (4





2)

ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION TOOL NO.
TOOL NAME
5-8840-2155-0
Bearing remover 5-8840-2159-0
Mainshaft end bearing
installer
5-8840-2027-0
Puller 5-8840-0015-0
Bearing
remover/installer
5-8840-2160-0
Holding fixture 5-8840-2797-0
Rear case oil seal
installer
5-8840-0003-0
Holding fixture base 5-8840-0026-0
Front cover oil seal
installer
5-8840-2156-0
Wrench 9-8522-1165-0
Mainshaft collar remover
5-8840-0047-0
Tork bit wrench
(T–45) 5-8840-0007-0
Driver handle

7B1-76 MANUAL TRANSMISSION

Transmission Case
Major Component


RTW47BLF000101

Legend

(1) Gear Control Box Assembly and Gasket (8) Front Cover (with Oil Seal)
(2) Rear Case Assembly (9) Top Gear Bearing Snap Ring
(3) Intermediate Plate with Gear Assembly (10) Release Bearing : C24NE
(4) Transmission Case (11) Shift Fork : C24NE
(5) Release Bearing (with Spring): 4JH1-TC (12) Fulcrum Bridge : 6VE1
(6) Shift Fork: 4JH1-TC (13) Release Bearing : 6VE1
(7) Counter Front Bearing Snap Ring (14) Shift Fork : 6VE1

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)

7B1-84 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).