transmission oil ISUZU TF SERIES 2004 Repair Manual

MANUAL TRANSMISSION 7B1-47


226RS031
9. Install needle bearing (18), 1st block ring (17), 1st
outside ring (16), 1st inside ring (15), and 1st gear
(14).


Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.


The 1st gear dog teeth must be facing the
transmission front side.

226RS053

Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
10. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
transmission front side.

226RS054
11. Apply engine oil to the mainshaft ball bearing (12)
and the mainshaft (26).
Install the ball bearing (12) and needle bearing collar
(11) to the mainshaft (26).
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.

226RS055

7B1-48 MANUAL TRANSMISSION

12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.

226RS056
13. Install 3rd block ring (8).
14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the 3rd gear side.

226RW221

226RS049
15. Select and install mainshaft snap ring(6) in the
following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.

226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.

7B1-50 MANUAL TRANSMISSION

Main Data and Specifications
General Specifications
MUA 5G MUA 5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"

7B1-54 MANUAL TRANSMISSION

TROUBLESHOOTING
1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper gear
oil NG
Mainshaft splines
Synchronizer clutch hub
splinesReplace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
Worn splines
Worn or scuffed gear tooth
contact surfaces
Flywheel pilot bearingWorn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)Worn or broken bearing(s)
OK
NG NG NG NG OK
OK
OK
Gear oil
TransmissionRealign the transmissionTransmission misalignment OK
NG

MANUAL TRANSMISSION 7B1-55

2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)Worn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)Worn, chipped, or cracked
gear(s)
NG NG NG NG OK
OK
OK OK
Gear oil (Metallic rattling)

7B1-56 MANUAL TRANSMISSION

2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OKNG NG NG NG
OK OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxWorn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG NG
OKShift block sleeve movement

7B1-60 MANUAL TRANSMISSION

4. OIL LEAKAGE

Checkpoint Trouble Cause Countermeasure

Gear oilReplace the gear oilImproper gear oil
Drain plug and/or filler plugTighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OKNG NG NG
OK OKOil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
Worn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil sealReplace the oil seal
Replace the gasket(s)
Worn or scratched oil seal
Defective or improperly
installed gasket(s)
OK
NG NG NG NG
OK OKGaskets

MANUAL TRANSMISSION 7B1-61

Special Tools (4





2)

ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION TOOL NO.
TOOL NAME
5-8840-2155-0
Bearing remover 5-8840-2159-0
Mainshaft end bearing
installer
5-8840-2027-0
Puller 5-8840-0015-0
Bearing
remover/installer
5-8840-2160-0
Holding fixture 5-8840-2797-0
Rear case oil seal
installer
5-8840-0003-0
Holding fixture base 5-8840-0026-0
Front cover oil seal
installer
5-8840-2156-0
Wrench 9-8522-1165-0
Mainshaft collar remover
5-8840-0047-0
Tork bit wrench
(T–45) 5-8840-0007-0
Driver handle

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

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