Transmission ISUZU TF SERIES 2004 Workshop Manual

7B1-28 MANUAL TRANSMISSION

(21) 5th Block Ring (26) Reverse Gear
(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate

MANUAL TRANSMISSION 7B1-29

Disassembly
1. Use a pair of snap ring pliers to remove the bearing
snap ring (1).
2. Set the bearing remover 5-8840-2155-0 and puller
5-8840-2027-0 to the bearing (2) and the mainshaft
end to remove the ball bearing (2).
262L100001
3. Remove the bearing snap ring (3), clip (5),
speedometer drive gear (4), retainer snap ring (6)
and retainer (7).
4. Remove thrust plate (8) and thrust washer and lock
ball (9).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (10).

226RS004

6. Remove the reverse idler gear assembly (11) from
the intermediate plate (30).

226RS005
7. Remove idle shaft pin (12), thrust washer (13),
reverse idler gear (14), and reverse idler shaft (15).
8. Use a pair of snap ring pliers to remove the snap
ring (16).
9. Attach a universal puller to the counter gear shaft.
Use a universal puller to remove the ball bearing
(17) and the counter 5th gear (18).

226RS006
10. Remove counter reverse gear (19).

7B1-30 MANUAL TRANSMISSION

11. Remove 5th gear (20), 5th block ring (21), and
needle bearing (2 piece type) (22).

226RS007
12. Remove the mainshaft nut (23) 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.
226RW212

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 (23).
226RW211

MANUAL TRANSMISSION 7B1-31

13. Use screw drivers between the reverse gear (26)
and bearing plate (28) to remove the Rev-5th
synchronizer assembly (24) together with reverse
block ring (25) and reverse gear (26).

226RS010
14. Remove needle bearing (27).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(28) from the
intermediate plate.

220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).


226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate (30) toward the rear of
the transmission to remove it.
The bearing snap ring (29) 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 (30) on the gear
assembly.
226RW212

7B1-32 MANUAL TRANSMISSION

2. Install bearing snap ring (29).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (28).
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 (27), reverse gear (26), and
reverse block ring (25). 5. Assemble rev-5th synchronizer assembly (24) 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 (24) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.

226RS013

226RS049

MANUAL TRANSMISSION 7B1-33

6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).

226RS015
This will prevent the mainshaft from turning.
7. Install the new mainshaft hub nut.
Use the mainshaft nut wrench 5-8840-2156-0 to
tighten the mainshaft nut (23) to the specified
torque.
Torque: 137 N




m (14 kg




m/101 lb




ft)
226RW214


8. Use a punch to stake the mainshaft nut (23).

226RW153
9. Install needle bearing (22), 5th block ring (21), and
5th gear (20).
10. Apply engine oil to the counter reverse gear (19) and
the reverse gear (26).
Install the counter reverse gear (19) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.

226RW151

7B1-34 MANUAL TRANSMISSION

11. Install the counter 5th gear (18) to the counter shaft.

226RS019
12. Install ball bearing (17) and bearing snap ring (16)
by performing the following steps:


Select the snap ring which will provide the
minimum clearance between the ball bearing
and the snap ring.

226RS020


There are six snap ring sizes available.
The snap rings are color‐coded to indicate
their thickness.

226RS021
Ball Bearing and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)

Snap Ring Availability
Thickness Color Coding
1.1 mm (0.043 in) White
1.2 mm (0.047 in) Yellow
1.3 mm (0.051 in) Blue
1.4 mm (0.055 in) Pink
1.5 mm (0.059 in) Green
1.6 mm (0.063 in) Brown


Use a pair of snap ring pliers to install the snap
ring(13) to the counter gear shaft.
The snap ring must be fully inserted into the
counter gear shaft snap ring groove.
13. Assemble reverse idler shaft (15), reverse idler gear
(14), thrust washer (13), and idle shaft pin (12) into
reverse idler gear assembly (11).
The trust washer should be assembled as oil groove
faces to gear side.

MANUAL TRANSMISSION 7B1-35

14. Select reverse idler gear snap ring (10) which will
provide the minimum clearance between the
intermediate plate (30) and the snap ring (10).

226RS022


There are three snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)

Snap Ring Availability
Thickness Color Coding
1.2 mm (0.047 in) White
1.3 mm (0.051 in) Yellow
1.4 mm (0.055 in) Blue

226RS021


Use a pair of snap ring pliers to install the snap
ring to the reverse idler shaft.
The snap ring must be fully inserted into the
reverse idler shaft snap ring groove.
15. Install thrust washer and lock ball (9) by performing
the following steps:


Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in))

Measure clearance "A" as shown in the figure.

226RS023


Select appropriate thrust washer from chart.


There are four thrust washer sizes available.

Thrust Washer Availability
Thickness
mm (in) Color
CodingA mm (in) Clearance
mm (in)
7.9 (0.311) White 8.05 - 8.1
(0.317-0.319) 0.15 - 0.25
(0.006-0.010)
8.0 (0.315) Yellow8.1 - 8.2
(0.319-0.323) 0.1 - 0.25
(0.004-0.010)
8.1 (0.319) Green8.2 - 8.3
(0.323-0.327) 0.1 - 0.25
(0.004-0.010)
8.2 (0.323) Blue 8.3 - 8.36
(0.327-0.329) 0.1 - 0.21
(0.004-0.008)


The thrust washers are color coded to indicate
their thickness as shown in the figure.

7B1-36 MANUAL TRANSMISSION


226RS024


Apply grease to the thrust washer and the lock
ball.


Install the thrust washer and the lock ball.
16. Install thrust plate (8) and retainer (7).
17. Install the retainer snap ring (6), clip (5),
speedometer drive gear (4) and bearing snap ring
(3).
18. Apply engine oil to the bearing (2) inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing (2) to the mainshaft.
226L100002
19. Install the bearing snap ring (1).

MANUAL TRANSMISSION 7B1-37

Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View


226RS026