Transmission ISUZU TF SERIES 2004 Workshop Manual

WORKSHOP MANUAL

TF SERIES




MANUAL TRANSMISSION
(MSG MODELS)





SECTION 7B

MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION
(MSG MODELS)
TABLE OF CONTENTS
PAGE
Main Data and Specifications .................................................................................... 7B - 2
General Description.................................................................................................... 7B - 3
Torque Specification .................................................................................................. 7B - 4
Repair Kit .................................................................................................................... 7B - 6
Removal and Installation ........................................................................................... 7B - 7
Disassembly ............................................................................................................... 7B - 15
Inspection and Repair ............................................................................................... 7B - 25
Reassembly ................................................................................................................ 7B - 29
Special Service Tool .................................................................................................. 7B - 42

7B-2 MSG MODEL
MAIN DATA AND SPECIFICATIONS

Transmission type Fully synchronized 5-forward gears with a constant
mesh type reverse gear.

Transmission Control Direct control with the gear shift lever on the floor.

Gear ratio MSG5K
1st : 4.122
2nd : 2.493
3rd : 1.504
4th : 1.000
5th : 0.855
Rev : 3.720

Oil capacity lit. (US gal.) 1.55(0.41)

Weight ; approx. kg(lbs) 33.3(73.8)

MSG MODEL 7B-3
GENERAL DESCRIPTION


The MSG type transmission is fully synchronized 5-speed unit with blocking ring type synchronizers and a constant
mesh type reverse gear.
The unit consists principally of a case with an integral clutch housing, intermediate plate, rear cover and gears.
The top of the rear cover is a quadrant box containing the transmission control mechanism.
The case and rear cover are cast aluminum alloy to reduce weight.

MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before
you begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.

7B-8 MSG MODEL


Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.





Rear Propeller Shaft (Single Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion
side

1.
2. Remove the propeller shaft from the transmission main
shaft spline

2.





Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation
procedure.
2. Remove the 2nd propeller shaft flange yoke bolts at the
drive pinion side

1.
3. Remove the center bearing retainer bolts

2 .
4. Remove the 1st propeller shaft with the center bearing and
the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle
until the spline yoke is free of the transmission main shaft.



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




Slave Cylinder
Remove the slave cylinder from the transmission case.

MSG MODEL 7B-9

Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.





Starter Motor
Remove the starter motor motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the transmission
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative
efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.

7B-10 MSG MODEL




3) Manually move the transmission as far as possible toward
the rear of the vehicle (into the space between the No.3
crossmember
3 and the floor panel 4 .
4) Lower the clutch housing end of the transmission toward the
transmission jack.
The rear of the transmission is supported by the No.3
crossmember at this time.
5) Firmly grasp the transmission rear cover (1st mechanic).
Raise the transmission jack toward the transmission (2nd
mechanic).
Carefully lower the transmission onto the transmission jack.
The transmission must be centered on the transmission
jack.




8. Carefully pull the transmission jack with the transmission
from beneath the vehicle.

MSG MODEL 7B-11
Important Operations - Installation
Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
installation procedure.





Transmission
1. Apply a thin coat of molybdenum disulfide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into
position behind the engine.





4. Slowly operate the transmission jack to raise the
transmission until the rear of the transmission is at the
same level as the No.3 crossmember
1 .
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3
crossmember and the floor panel
2 .



6. Slowly raise the transmission jack until the front of the
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be the
same.
7. Install the gear control box the transmission.
8. Align the top gear shaft spline with the clutch drive plate
spline.
9. Install the transmission to the engine.
Tighten the transmission nuts and bolts as shown in the
figure.

7B-12 MSG MODEL


RTW37BLF000901



10. Install the rear mounting rubber 3 to the transmission 2.
Install the rear mounting rubber
3 to the No.3
crossmember
4.
11. Tighten the rear mounting rubber nuts
1 to the specified
forque.
Rear Mounting Rubber Nut Torque N

m (kgf

m/lb

ft)
41 (4.2 / 30)
Mounting Bolt Torgue N
m (kgf
m/lb
ft)
41 (4.2 / 30)