engine remove ISUZU TF SERIES 2004 Workshop Manual

MANUAL TRANSMISSION 7B1-19

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
(6)(11) from the transmission case.
4. Remove the shift fork (7)(12), 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 (9) and gasket from the
transmission case.
9. Remove snap ring (8) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (10) fixing top gear bearing.

226RS001
11. Remove the speedometer sensor (2).
Remove the plate (2).
Remove the driven gear bushing and driven gear
(2).
NOTE : Apply a reference mark to the driven gear
bushing before removal.
12. Remove gear control box assembly (1).

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

7B1-66 MANUAL TRANSMISSION

6. Remove gear control lever (5).
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.
9. Remove front propeller shaft (7).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
401RS023
10. Loosen the front exhaust pipe fixing nuts (8) at the
engine side but not remove them. (Diesel engine
only)
150R300004
11. Remove the exhaust pipe (9). (6VE1 only)
RTW37ASH000101
12. Disconnect harness connectors and clips on the
transfer.


Actuator connector


Car Speed Sensor

810R300069

Legend
(1) Neutral Switch Connector: Transmission
(2) Back up Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W - 4W Switch Connector
(6) Neutral Switch Connector: Transfer

MANUAL TRANSMISSION 7B1-67

13. Remove transmission-transfer fixing bolts (10), and
remove the transfer assembly (11) from the
transmission.
14. Disconnect harness connectors and clips on the
transmission.


Neutral switch; Transmission

Back up Switch

2W-4W Switch


Neutral Switch; Transfer
15. Remove the fuel pipe brackets (12) with pipes from
the transmission (18).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly



6VE1, C24NE
Scan-2
16. Remove slave cylinder (13) and put aside it.
220LV019
17. Support transmission with a transmission jack.
220RS0001
18. Remove engine rear mount nuts (14) from
transmission crossmember (15).

7B1-68 MANUAL TRANSMISSION

19. Remove engine rear mount bolts fixing
transmission.
220R300009
20. Remove the middle part of transmission
crossmember (15) by removing four fixing bolts and
nuts.
501R30007
21. Take out the rear support rubber. 22. Remove starter (16). (Diesel engine only)
060L100070
23. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.

MANUAL TRANSMISSION 7B1-69

NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064


220RW019

Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
24. Remove transmission retaining nuts and bolts(17).
Remove transmission assembly (18) from the
vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft with the clutch driven plate
spline.

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.

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)