engine oil ISUZU TF SERIES 2004 Workshop Manual

MSG MODEL 7B-31



Important Operations
2. Needle Bearing
3. 2nd Gear
1) Apply the engine oil to the 2nd needle bearing and the 2nd
gear.
2) Install the needle bearing and the 2nd gear to the
mainshaft.
The dog teeth of the 2nd gear must be facing the rear side
of the transmission.


5. 1st-2nd Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The outside sleeve heavy chamfering must be facing the
rear of the transmission.
1 Chamfer Angle = 30


2 Chamfer Angle = 45





7. Needle Bearing Collar
Use a bench press and the collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)



8. Needle Bearing
9. 1st Gear
1) Apply the engine oil to the 1st needle bearing and the 1st
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 1st gear must be facing the front side
of the transmission.


10. 1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the 1st gear side.

7B-32 MSG MODEL



11. Mainshaft Ball Bearing
1) Apply the engine oil to the ball bearing inside
circumference.
2) Use a bench press and the bearing installer to install the
bearing.
The bearing snap ring groove must be facing the front o
f
the transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)




12. Needle Bearing
13. 3rd Gear
1) Apply the engine oil to the 3rd needle bearing and the 3rd
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 3rd gear must, be facing the front side
of the transmission.






15. 3rd-4th Synchronizer Assembly
1)
Apply the recommended lubricating oil to the clutch hub
spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve light chamfering

1 and the clutch hub heavy
boss

2 must be facing the rear of the transmission.



16. Mainshaft Snap Ring
1) Select the snap ring which will provide the minimum
clearance between the mainshaft and the snap ring.
There are four snap ring sizes available.
The snap rings are numbered to indicate their thickness.
Mainshaft and Snap Ring Clearance mm(in)
Standard
0 - 0.05 (0.002)


Snap Ring Availability mm(in)Thickness Identification Number
1.50 (0.059) 1
1.55 (0.061) 2
1.60 (0.063) 3
1.65 (0.065) 4
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.

MSG MODEL 7B-35


Important Operations
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque Nm(kgfm/lbft)
18.6 (1.9 / 13.7)



3) Set the mainshaft with gear assembly

1 and the counter
gear assembly

2 to the holding fixture
3.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the
counter shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the
counter gear ball bearings.



6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque Nm (kgfm/lbft)
107.8 (11 / 79.6)



9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse
gear side.

7B-36 MSG MODEL


13. Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer

1 and the insert short side
2
must be facing to the rear side of the transmission.


14. Mainshaft Lock Nut and Washer
1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use the lock nut wrench to tighten the lock nut to the
specified torque.
Lock Nut Wrench : 5-8840-0353-0 (J-36629)
Lock Nut Torque Nm(kgfm/lbft)
107.8 (11 / 79.6)



22. Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque N
m(kgf
m/lb
ft)
107.8 (11 / 79.6)



18. Thrust Washer and Lock Ball
23. Thrust Washer Thrust Ring
24. Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the
thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.


3) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.

MSG MODEL 7B-41

RTW47BSH000201
Important Operations
2. Rear Cover with Oil Seal
1)
Align the pins at the lower side of the rear cover with the
holes in the lower side of the intermediate plate.
2)
Apply recommended liquid gasket or its equivalent to the
rear cover fitting surfaces.
3) Install the rear cover to the intermediate plate.
4) Tighten the rear cover bolts to the specified torque.
Rear Cover Bolt Torque N
m(kgf
m/lb
ft)
37.2 (3.8 / 27.5)
Note:
Take care not to twist or puncture the oil seal during the
installation procedure.


RTW47BSH000301

3. Transmission Case
4. Bearing Snap Ring
1) Apply the engine oil to the transmission case top gear shaft
ball bearing fitting faces.
2)
Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4) Pull the top gear shaft from the transmission case until the
ball bearing snap ring grove protrudes from the
transmission case front cover fitting faces.
5) Use a pair of snap ring pliers to install the snap ring to the
ball bearing.



6. Front Cover with Oil Seal
1) Clean and apply recommended liquid gasket or its
equivalent to the through bolt threads.
2) Install the new gasket and tighten the new cover bolt to the
specified torgue.
Front Cover Bolt Torgue N
m(kgf
m/lb.ft)
24.5 (2.5 / 18.1)









RTW47BSH000101
10. Shift Fork
Apply molybdenum disulfide type grease to the areas as
shown in the figure and install shift fork (Diesel engine).

7B1-18 MANUAL TRANSMISSION

Transmission Case
Major Component
RTW37BLF0005
Legend

(1) Gear Control Box Assembly and Gasket (9) Front Cover (with Oil Seal)
(2) Speedometer Sensor and Driven Gear (10) Top Gear Bearing Snap Ring
(3) Rear Cover Assembly (11) Release Bearing : C24NE
(4) Intermediate Plate with Gear Assembly (12) Shift Fork : C24NE
(5) Transmission Case (13) Fulcrum Bridge : 6VE1
(6) Release Bearing (with Spring) : Diesel engine (14) Release Bearing : 6VE1
(7) Shift Fork : Diesel engine (15) Shift Fork : 6VE1
(8) Counter Front Bearing Snap Ring

MANUAL TRANSMISSION 7B1-21

7. Install the speedometer sensor (2).
Torque: 27 N




m (2.8 kg




m/20 lb




ft)
225R300001
8. Install top gear bearing snap ring (10) and counter
front bearing snap ring (8).


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.
9. Front cover with oil seal (9).
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
10. Install a new gasket and front cover (9) to the
transmission case.
NOTE: Take care not to damage the oil seal.
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 before
tightening it.
Tighten six front cover bolts to the specified torque.
Torque: 25 N





m (2.6 kg





m/19 lb





ft)
11. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (7).
(Diesel engine, C24NE)
F07L100026

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

7B1-36 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).

7B1-44 MANUAL TRANSMISSION

Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.

226RS042


Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.

Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play


Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)


226RS043

Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).


Apply engine oil to the bearing inner and outer
circumferences.

Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.

226RS044
2. Install front roller bearing (28) by performing the
following steps.

Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).


Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.