manual transmission ISUZU TF SERIES 2004 Workshop Manual

7B1-70 MANUAL TRANSMISSION

4. Install the transmission assembly (18) to the engine.
Tighten the transmission nuts and bolts as shown in
the figure.


Diesel engine
RTW37BLF000901

MANUAL TRANSMISSION 7B1-71

6VE1
RTW37BLF0001

7B1-72 MANUAL TRANSMISSION




RTW37BLF000201

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.

220RS006

MANUAL TRANSMISSION 7B1-73

6. Install starter(16).(Diesel engine)
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 on the transmission
and tighten the bolts to the specified torque.
Torque: 50 N




m (5.1 kg




m/37 lb




ft)
8. Install the middle part of transmission crossmember
(15) 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 (14).
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 (13) 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 on the transmission.
Install the fuel pipe assembly to the fuel pipe
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-2
12. Connect transmission harness connectors and clips.
Connector: transfer neutral switch, 2W - 4W switch,
backup switch, transmission neutral switch.
810R300069

Legend
(1) Neutral Switch Connector: Transmission
(2) Backup Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W - 4W Switch connector
(6) Neutral Switch Connector: Transfer
13. Apply grease (BESCO L2 or equivalent) on the
splined portion of the output shaft.
14. Connect the transfer to the transmission.

7B1-74 MANUAL TRANSMISSION

15. Install the transmission-transfer bolts and nut and
tighten them to the specified torque.
Torque: 41 N





m (4.2 kg





m/30 lb





ft)
261R300005
18. Install the exhaust pipe (9). (6VE1)
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
RTW37ASH000101
19. Install front propeller shaft (7).
Refer to the section “Front Propeller Shaft”.
20. Install rear propeller shaft (6).
Torque: 63 N




m (6.4 kg




m/46 lb




ft)
21. Install the center bearing on crossmember.
Torque: 69 N




m (7.0 kg




m/51 lb




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





m (1.9 kg





m/14 lb





ft)

MANUAL TRANSMISSION 7B1-75

21. 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
24. Install front floor console (3) and rear floor console
(2).
25. 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.
26. Connect battery ground cable.

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

MANUAL TRANSMISSION 7B1-77

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 (5)
from the transmission case.
4. Remove the shift fork, 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 (8) and gasket from the
transmission case.
9. Remove snap ring (7) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (9) fixing top gear bearing.

226RS001
11. Remove gear control box assembly (1).
12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).

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)