oil ISUZU TROOPER 1995 Workshop Manual

78-16 MANUAL TRANSMISSION
7.
mm{in)
MAX. 1.5 (0.06)
MAX. 1.5 10.06)
MIN. 4 (0.16)
MIN. 4 (0.16)
Fig. 78-29
Speedometer driven gear and Speedometer
sensor
• Install the 0-ring to the speedometer driven
gear bushing.
• Install the driven gear to the speedometer
driven gear bushing.
• Install the speedometer driven gear assembly
to the transfer rear cover (Fig. 78-30).
• Install the plate to the transfer rear cover.
l"i't I Torque N·m (lb·ft) ~ _...:.____---~... ___ _ 15 (11)
• Install the speedometer sensor.
I~I_T_o_rq...;_u_e_N_·_m_(_lb_·ft_l----~. ___ 2_7_(2_0_) __ _
Plate Bolt
~
Fix1ing type Drive gear Driven gear
No. of teeth
X No. of teeth
6 X 19
Fig. 78-30
6. Snap ring; top gear bearing
5. Snap ring; counter front bearing
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
4. Front cover (with oil seal)
Oil seal
replacement
• Remove the oil seal from the front cover.
c:::;J • Apply engine oil to the oil seal outer
D circumference.
• Apply recommended grease to the oil seal lip.
1®.1• Use the oil seal installer to install the rear seal to
the
front cover (Fig. 78-31 ).
Oil seal installer: J-29769
• Install a new gasket and front cover to the
transmission case.
'\f7 NOTE:
"+({ Take care not to damage the oil seal.
Notes when tightening the bolt:
• After Gleaning the bolt hole, dry it thoroughly
with air.
• After Gleaning the screw face of a removed bolt
or new one, dry it thoroughly. Apply rec­
omme~nded liquid gasket (LOCTITE 242) or its
equivalent before tightening it.
Tighten six
new front cover bolts to the
specified torque.
1~1 Torque N·m (lb·ft) 25 (18)
..

78-20 MANUAL TRANSMISSION
Fig. 78-41
~ DETENT SPRING FREE LENGTH
• Use a vernier caliper to measure the detent
spring free length (Fig. 78-42).
If the measured value is less than the specified
limit, the
detent spring must be replaced.
Detent spring free length
mm (in)
Standard Limit
26.8 (1.06) 26.2 (1.03)
Fig. 78-42
~ DETENT SPRING TENSION
• Use a spring tester to measure the valve spring
tension (Fig. 78-43).
If the measured value is less than the specified
limit, the valve spring must be replaced.
Valve spring tension
N (lb)
Compressed height Standard
20 mm 87.2-97.1
(0.787 in) (19.6-21.8) Fig.
78-43
l•!•l REASSEMBLY
12. Intermediate plate and gear assembly
10.
1st-2nd shift arm
9. 3rd-4th shift arm
• Hold Cl round bar against the shift rod end lower
face to protect it against damage.
• Install a new spring pin.
Discard the used spring pin.
Fig. 78-44
8. 3rd-4th shift rod
11. Interlock pin
• Install the interlock pin to the shift rod.
• Install the shift rod together with the interlock
pin
to the intermediate plate.
Do
not allow the interlock pin to fall from the
shift
rod.
7. 1st-2nd shift rod
6. Rev-5th shift arm and reverse inhibitor
EJ • Apply oil to the reverse inhibitor inner surface.
5. Rev-5th shift rod
4. Spring
..

78-22 MANUAL TRANSMISSION
REVERSE GEAR AND 5TH GEAR
6
26 22
23
20
-~~ 19
-~;(>~-~~·
<:/'-. ~~2~
)<., ""-, 15~ 13
7 ~
Disassembly steps
1.
Oil seal collar 2. Ball bearing
3. Retainer
4.
Thrust plate
5. Thrust washer and lock ball 6. Reverse idler gear snap ring 7. Reverse idler gear assembly 8. Reverse idler shaft 9. Reverse idler gear 10. Thrust washer
11. Idle shaft pin
12. Bearing snap ring
13. Ball bearing
14. Counter 5th gear
15. Counter reverse gear
16. 5th gear 17.
5th block ring
18. Needle bearing
19.
Mainshai't nut 20. Rev-5th synchronizer assembly
21. Reverse block ring 22. Reverse !~ear 23. Needle bearing
24. Bearing plate and screw
25. Bearing snap ring
26. Intermediate plate
Reassembly !lteps To reassemble, follow the disassembly !iteps in the reverse order.
Fig. 78-46
5
..

l•!•l DISASSEMBLY
1. Oil Seal Collar
2. Ball bearing
3. Retainer
I®J • Set the retaining ring remover to the retainer
and the mainshaft end (Fig. 78-47).
• Remove the retainer together with the bearing
and the
oil seal collar.
The puller may be used in place ofthe retaining
ring remover.
Retainer Remover: J-37222
Puller: J-8433
Fig. 78-47
4. Thrust plate
5. Thrust washer and lock ball
6. Reverse idler gear snap ring
J-8433
• Use a pair of snap ring pliers to remove the
snap ring (Fig. 78-48).
Fig. 78-48
7. Reverse idler gear assembly
• Remove the reverse idler gear assembly from
the intermediate plate (Fig. 78-48a).
MANUAL TRANSMISSION 78 23
Fig. 78-48a
8. Reverse idler shaft
9. Reverse idler gear
1
0. Thrust washer
11.
Idle shaft pin
12. Bearing snap ring
• Use a pair of snap ring pliers to remove the
snap rings.
13. Ball bearing
14. Counter 5th gear
• Engage the Rev. 5th synchronizer with the 5th
gear.
• Attach the puller to the counter gear shaft.
• Pull the reverse shaft toward you and hold it.
• Use the puller to remove the ball bearing and
the counter 5th gear (Fig. 78-49).
Fig. 78-49
15. Counter reverse gear
16. 5th gear
17. 5th
block ring
18.
Needle bearing
• Remove the needle bearing (2 piece type) (Fig.
78-50).

78-26 MANUAL TRANSMISSION
Fig. 78-59
19. Mainshaft nut
1) Mesh the 1st-2nd synchronizer with both the
1st and 3rd gears
(double engagement) (Fig.
78-60).
2)
~3)
This will prevent the mainshaft from turning.
Install the new mainshaft hub nut.
Use the mainshaft
nut wrench to tighten the
mainshaft
nut to the specified torque (Fig.
78-61).
Wrench: J-37219
Fig. 78-60
Fig. 78-61
1~1 Torque N·m (lb·ft) 137 (101)
4) Use a punch to stake the mainshaft nut (Fig. ~
78-62).
18. Needle bearing
17. 5th
block ring
16. 5th gear
Fig. 78-62
15. Counter reverse gear
Cl • Apply engine oil to the counter reverse gear
L.::::::.l and the reverse gear.
8 • Install the counter reverse gear to the counter
gear.
The reverse gear projection
must be facing the
intermediate
plate. (Fig. 78-63).
Fig. 78-63
14. Counte1· 5th gear
• Install the counter 5th gear to the transmission
(Fig. 78-64).
13. Ball bearing
•

78-28 MANUAL TRANSMISSION
• 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.
Fig. 78-68
5. Thrust washer and lock ball
l'fil • Use a thickness gauge to measure the
1.!::.1 clearance between the 5th gear and the thrust
washer.
5th gear and thrust washer
clearance
Standard mm (in) 10.10-0.25 (0.004 -0.01 0)
• Measure clearance "A" (Fig. 78-69).
A
Fig. 78-69
• Select appropriate thrust washer from chart.
• There are four thrust washer sizes available.
•
The thrust washers are color-coded to indicate
their thickness (Fig.
78-70).
Thrust washer availability
Thickn,ess Color-A Clearance
mm (in)
coding mm (in) mm (in)
7.9 (0.3:11) White 8.05-8.1 0.15-0.25
(0.317-0.319) (0.006-0.01
0)
8.0
(0.3:15) Yellow 8.1-8.2 0.1-0.25
(0.319-0.323) (0.004-0.01
0)
8.1 (0.3:19) Green 8.2-8.3 0.1 -0.25
(0.323-0.327) (0.004-0.01 0)
8.2 (0.323) Blue 8.3-8.36 0.1-0.21
(0.327-0.329) (0.004-0.008)
Fig. 78-70
1-ool • Apply grease to the thrust washer and the lock
ball.
• Install!
the thrust washer and the lock ball.
4. Thrust plate
3. Retainer
2. Ball bearing
D • Apply engine oil to the bearing inner and outer
~ circumference.
lia\1 • Use the installer to install the ball bearing to the
~ mainshaft in proper direction (Fig. 78-71 ).
Installer: J-37223
1. Oil seal collar
Fig. 78-71
•

78-34 MANUAL TRANSMISSION
Fig. 78-88
l•!•l REASSEMBLY
30. Counter gear shaft
29. Center roller bearing
r:::::1 • Apply engine oil to the bearing inner and outer
L.:::.l circumferences.
• Install the roller bearing in the proper direction
(Fig. 78-89).
'q7 NOTE:
VI Check that outer race moves only in the direction
of arrow.
Roller Beering
t
Fig. 78-89
28. Front roller bearing (fig. 78-90)
• Use bearing installer to install the front roller
bearing inner race to the counter gear shaft.
• Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission
front side.
1®..1• Use bearing installer to install the ring.
Bearing
installer: J-35283
=
rr=:=n--Ring
~ Outer race and ~Roller assembly
c:::Jb..-lnner race
Fig. 78-90
27. Bearing snap ring
26. Mainshaft
25. Needle bearing
24. 2nd gear
D • Apply engine oil to the needle bearing and the
L.:::.l 2nd gear thrust surfaces.
• Install the needle bearing and the 2nd gear to
the mainshaft.
r:;::] The 2nd gear dog teeth must be facing the
~ transmission rear side (Fig. 78-91 ) .
Fig. 78-91
23. 2nd inside ring (Fig. 78-92)
22. 2nd
outside ring (Fig. 78-92)
21. 2nd
bloc:k ring (Fig. 78-92)
.. Rear
side
D • Apply engine oil to the synchronizer ring
L.:::.l friction surfaces.
•

78-36 MANUAL TRANSMISSION
Snap ring availability mm (in)
Thickness
Color-coding
1.80 (0.071)
White
1.85
(0.073) Yellow
1.90 (0.075)
Blue
•
Use a pair of snap ring pliers to install the snap
ring
to the mainshaft (Fig. 78-97).
The snap ring
must be fully inserted into the
mainshaft snap ring groove.
Fig. 78-97
18. Needle bearing (Fig. 78-98)
17. 1st
block ring (Fig. 78-98)
16. 1st outside ring (Fig. 78-98)
15. 1st inside ring (Fig. 78-98)
14. 1st gear (Fig. 78-98)
C1 • Apply engine oil to the needle bearing, 1st gear
L::l thrust surfaces and synchronizer ring friction
surfaces.
• Install the needle bearing and the 1st gear to
the mainshaft.
1 .. 1 The 1st gear dog teeth must be facing the
transmission
front side.
c:;! j;::::J
Inside ring
Outside ring .
Block Zig I
~~ .
Fig. 78-98
13. 1st gear thrust bearing
• Install the thrust bearing and the race to the
mainshaft (Fig. 78-99).
The
thrust bearing side must be facing the
transmission
front side.
Fig. 78-99
12. Mainshaft ball bearing
11.
Needle bearing collar
1~·1 • Apply engine oil to the ball bearing and the
mainshaft.
1 .. 1• Install the ball bearing and collar to the
mainshaft.
The
ball bearing snap ring groove must be
facin~1 the transmission rear side.
1®..1 • Use a bench press to slowly force the collar into
place (Fig. 78-1 00).
Installer:
J-6133-01

MANUAL TRANSMISSION 78-37
Fig. 78-100 Fig. 78-102
10. Needle bearing
9. 3rd gear
• Apply engine oil to the needle bearing and the
3rd gear
thrust surfaces.
• Install the needle bearing and the 3rd gear to
the mainshaft.
The 3rd gear dog teeth
must be facing the
transmission
front side (Fig. 78-101 ).
Front side
..
Fig. 78-101
8. 3rd block ring
7. 3rd-4th synchronizer assembly (Fig. 78-102,
Fig. 78·103)
1) Check that the inserts @ fit snugly into the
block ring insert grooves.
2) Check that the insert springs @ are fitted to
the inserts as shown in the illustration.
3) Check that the clutch hub@and the sleeve®
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. Fig.
78-103
6. Mainshaft snap ring
l"fil • Select the snap ring which will provide the
l..!l!l minimum clearance between the 3rd-4th clutch
hub and the snap ring (Fig. 78-1 04).
There are three snap ring sizes available.
The snap rings are color-coded to indicate their
thickness (Fig.
78-1 05).
Clutch
hub and snap ring clearance mm (in)
Standard
0-0.1 (0-0.004)
Snap
ring availability mm (in)
Thickness
Color-coding
1.80 (0.071)
White
1.85
(0.073) Yellow
1.90 (0.075) Blue

MANUAL TRANSMISSION 78-39
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Transmission type
Transfer case
Control method
Gear ratio: Transmission
1st
2nd
3rd
4th
5th
Rev.
:Transfer High
low
Transmission oil capacity lit. (US qt)
Transfer
oil capacity lit. (US qt)
Type
of lubricant Fully
synchronized
5-forward gears
Constant mesh type gears shifting between the
2
and 4 wheel drive mode. Synchronized type gears
between
"low" and "high"
Remote control with the gear shift lever on the floor.
3.767
2.248
1.404
1.000
0.809
3.873
1.000
2.283
2.95
(3.12)
1.45 (1.53)
Engine oil
Refer to chart in Section 0