manual transmission ISUZU TF SERIES 2004 Workshop Manual

7B1-80 MANUAL TRANSMISSION

12. Install the washer and snap pin. (6VE1)



RTW47BMH000201
13. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover,
joining it to the shift fork.

MANUAL TRANSMISSION 7B1-81

Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View



RTW47BLF000501
Legend

(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly

7B1-82 MANUAL TRANSMISSION

Disassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent balls
from the intermediate plate.

220RS011
2. Remove spring (4).
3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).


Hold a round bar against the shift rod end.

230RS003

Use a spring pin remover to remove the shift
arm spring pins from the shift arms and the shift
rods.


230RS0004


Be careful not to lose the interlock pins, when
pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.

230RS0005

Remove the rev-5th, 1st-2nd and 3rd-4th shift
rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).

MANUAL TRANSMISSION 7B1-83

Inspection and Repair
Make the necessary adjustments, and part
replacements if excessive wear or damage is
discovered during inspection.
Shift Arm Thickness

Use a micrometer to measure the shift arm
thickness.
If the measured value is less than the specified limit,
the shift arm must be replaced.

Shift Arm Thickness
Standard Limit
1st-2nd 9.60 - 9.85 mm
(0.378 - 0.388 in)
3rd-4th
Rev.5th 9.60 - 9.80 mm
(0.378 - 0.386 in) 9.0 mm
(0.354 in)

230RS006
Detent Spring Free Length


Use a vernier caliper to measure the detent spring
free length.
If the measured value is less than the specified limit,
the detent spring must be replaced.

Detent Spring Free Length
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)


SOUTH AFRICA 5th-Rev Only
Detent Spring Free Length
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in)

220RS012
Detent Spring Tension


Use a spring tester to measure the detent spring
tension.
If the measured value is less than the specified limit,
the detent spring must be replaced.

Detent Spring Tension
Compressed height Standard
20 mm (0.787 in) 87.2 - 97.1 N
(19.6 - 21.8 lb)

220RS013


SOUTH AFRICA 5th-RV Only
Detent Spring Free Length
Compressed Standard
Outer 20 mm (0.787 in) 93.5 – 103.3 N
(21.0 – 23.3 lb)
Inner 20 mm (0.787 in) 26.4 – 36.3 N
(5.9 – 8.2 lb)

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).

MANUAL TRANSMISSION 7B1-87

11. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).

226RS007
12. Remove the mainshaft nut (20) according to
following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
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Engage the 3rd-4th synchronizer with the 3rd
gear.


Engage the 1st-2nd synchronizer with the 1st
gear.

226RW210

Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut (20).
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7B1-88 MANUAL TRANSMISSION

13. Use screw drivers between the reverse gear (23)
and bearing plate (25) to remove the Rev-5th
synchronizer assembly (21) together with reverse
block ring (22) and reverse gear (23).

226RS010
14. Remove needle bearing (24).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(25) from the
intermediate plate.

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16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).


226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate (27) toward the rear of
the transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (27) on the gear
assembly.
226RW212

MANUAL TRANSMISSION 7B1-89

2. Install bearing snap ring (26).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (25).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N




m (1.5 kg




m/11 lb




ft)

220RW137
4. Install needle bearing (24), reverse gear (23), and
reverse block ring (22). 5. Assemble rev-5th synchronizer assembly (21) by
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
2. Check that the inserts (3) fit snugly into the
clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (21) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.

226RS013

226RS049