lock ISUZU TROOPER 1995 Workshop Manual

78-24 MANUAL TRANSMISSION
Fig. 78-50
19. Mainshaft nut (Fig. 7B-51)
• Engage the 3rd-4th synchronizer with the 3rd
gear.
• Engage the 1st-2nd synchronizer with the 1st
gear.
~~~· Attach the holding fixture to the mainshaft and
the counter gear.
~·
Holding fixture: J-37224
Base: J-3289-20
Use the mainshaft nut wrench to remove the
mainshaft
nut (Fig. 78-52).
Wrench: J-37219
Fig. 78-51
Fig. 78-52
20. Rev-5th synchronizer assembly
21. Reverse block ring
22. Reverse gear
• Use screw drivers between the reverse gear
and bearing plate to remove the Rev-5th
synchronizer assembly together
with reverse
block ring and gear (Fig. 78-53).
Fig. 78-53
23. Needle bearing
24. Bearing
plate and screw
1'?.3\1 • Use the torx bit wrench to remove the bearing
C::BJ plate screw from the intermediate plate (Fig.
78-54).
Torx bit wrench: J-37225 (T45).
Fig. 78-54
25. Bearing snap ring
26.
Intermediate plate
• Use the snap ring pliers ® to remove the
mainshaft bearing snap ring
CD (Fig. 7B-55).
• Hold the snap ring open with the pliers.
• Push the intermediate plate toward the rear of
the transmission to remove it.
The
b1~aring snap ring will come free.
•

Fig. 78-55
IL•I INSPECTION AND REPAIR
Refer to "TOP GEAR SHAFT, MAIN GEAR SHAFT, AND
COUNTER GEAR" in this section for inspection and
repair.
l•!•l REASSEMBLY
26. Intermediate plate
• Mesh the counter gear with the mainshaft
assembly.
1®.1• Install the holding fixture to the mainshaft and
the counter gear (Fig. 78-56).
Holding fixture: J-37224
Holding fixture base:
J-3289-20
• Place
the holding fixture (with the mainshaft
and the counter shaft) in a vise.
• Install the intermediate plate.
Fig. 78-56
25. Bearing snap ring
24. Bearing
plate and screw
rci1 • Apply recommended thread locking agents
l.:i!.l (LOCTITE 242) or its equivalent to each of the
bearing
plate screw threads.
Refer to
"RECOMMENDED THREAD LOCKING
AGENTS"
of the Section 0 in this manual.
MANUAL TRANSMISSION 78-25
1®.1• Tighten the screws to the specified torque (Fig.
78-57).
Torx bit wrench: J-37225 (T45)
1~1 Torque N·m (lb·ft) I
23. Needle bearing
22. Reverse gear
Fig. 78-57
21. Reverse block ring
15 (11)
20. Rev-5th synchronizer assembly (Fig. 7B·58 &
7B·59)
r=l1) Turn the clutch hub face CD toward the sleeve
~ groove ® on the outer circumference.
0 2) Check that the inserts ® fit snugly into the
1!!.!1 block ring insert grooves.
3) Check that the inserts springs@ are fitted to
the inserts
as shown in the illustration.
4) Check thatthe clutch hub@ and the sleeve®
slide smoothly.
5) Install the synchronizer assembly to the
mainshaft.
The clutch hub face (with the heavy boss)
must be facing the reverse gear side.
Reverse gear side
... F====I
Fig. 78-58
Rear
side

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
•

MANUAL TRANSMISSION 78-29
TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR SHAFT
2
29
Disassembly steps 1. Top gear shaft snap ring
2.
Top gear shaft
3.
Ball bearing
4. Needle bearing 5. Top block ring
6. Mainshaft snap ring
7.
3rd·4th synchronizer assembly 8. 3rd block ring
9. 3rd gear
10. Needle bearing
11. Needle bearing collar 12. Mainshaft ball bearing
13. 1st gear thrust bearing
14. 1st gear
15. 1st inside ring
16. 1st outside ring
17. 1st
block ring
18. Needle bearing
21
19
~~~
r-.J
20
19. Clutch hub snap ring 20. 1st-2nd synchronizer assembly 21. 2nd block ring
22. 2nd outside ring
23. 2nd inside ring
24. 2nd gear
25.
Needle bearing
26. Mainshaft
27. Bearing snap ring
28.
Front roller bearing
29. Center roller bearing
30. Counter gear shaft
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.
Fig. 78-72

78-30 MANUAL TRANSMISSION
1 .. !•1 DISASSEMBL V
1. Top gear shaft snap ring
• Use a pair of snap ring pliers to remove the
snap ring.
2. Top gear shaft
3. Ball bearing
li5il • Use a bench press and the bearing remover to
~ remove the ball bearing (Fig. 7B-73).
Bearing remover: J-22912-01
2-01
Fig. 7B-73
4. Needle bearing
5. Top block ring
6. Mainshaft snap ring
• Use a pair of snap ring pliers to remove the
snap ring
(Fig. 7B-74).
Fig. 7B-74
7. 3rd-4th synchronizer assembly
li5il • Use a bench press and the bearing remover to
~ remove the synchronizer assembly as a set -.
(Fig. 7B-75).
Bearing remover:
J-22912-01
• Disassemble
the synchronizer assembly
CD Springs
® Sleeve
@ Clutch hub
@ Inserts
8. 3rd block ring
9. 3rd gear
1
0. Needle bearing Fig.
7B-75
11.
Needle bearing collar
12. Mainshaft ball bearing
13. 1st gear thrust bearing
14. 1st gear
li0\1 • Use a bench press and the bearing remover to
~ remove the ball bearing (Fig. 78-76).
Bearing remover: J-22912-01
Fig. 7B-76
•

15. 1st inside ring
16. 1st outside ring
17. 1st block ring
18. Needle bearing
19. Clutch hub snap ring
• Use a pair of snap ring pliers to remove the
snap ring (Fig. 7B-77).
Fig. 7B-77
20. 1st-2nd synchronizer assembly
21. 2nd block ring
22. 2nd outside ring
23. 2nd inside ring
24. 2nd gear
rta\1 • Use a bench press and the bearing remover to
~ remove the 2nd gear together with synchroni-
zer
assembly (Fig. 7B-78).
Bearing remover:
J-22912-01
Fig. 7B-78
• Disassemble the synchronizer assembly
® Sleeve
® Clutch hub
@ Inserts
25. Needle bearing
26. Mainshaft
MANUAL TRANSMISSION 78-31
27. Bearing snap ring
28. Front roller bearing
rta\1 • Use a bench press and the bearing remover to
~ remove the front roller bearings (Fig. 7B-79).
Bearing remover:
J-22912-01
Fig. 7B-79
29.
Center roller bearing
30. Counter gear shaft
~ INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacement if excessive wear or damage is
discovered during inspection.
~ BLOCK RING AND DOG TEETH CLEARANCE
• Use a thickness gauge to measure the
clearance between the block ring and the dog
teeth (Fig.
7B-80).
If
the measured value exceeds the specified
limit, the block ring must be replaced.
Block
ring and dog teeth clearance mm (in)
Standard Limit
1.5
(0.059) 0.8 (0.032)
Fig. 7B-80

7B-32 MANUAL TRANSMISSION
~1ST-2ND SYNCHRONIZER (3-CONE)
• Use a thickness gauge to measure the
clearance between the block ring and the dog
teeth (Fig. 7B-81).
If the measured value exceeds the specified
limit, the 1st-2nd synchronizer assembly must
be replaced.
Block
ring and dog teeth clearance mm (in)
Standard Limit
1.5
(0.059) 0.8 (0.032)
Fig. 7B-81
~~~ BLOCK RING AND INSERT CLEARANCE
• Use a vernier caliper or thickness gauge to
measure the
clearance between the block ring
and the insert (Fig. 7B-82).
If the measured value exceeds the specified
limit, the block ring and the insert must be
replaced.
Block
ring and insert clearance mm (in)
Standard Limit
3rd-4th 3.46-3.74
(0.136-0.147)
4.0 (0.158)
1st-2nd
4.34-4.66 (0.171-0.183) 4.9 (0.193)
5th 3.59-3.91 (0.141-0.154) 4.1 (0.161)
Fig. 78-82
~ CLUTCH HUB AND INSERT CLEARANCE
• Use a thickness gauge to measure the
clearance between the clutch hub and the
insert ring (Fig. 7B-83).
If the measured value exceeds the specified
limit, the clutch hub and the insert must be
replaced.
Clutch
hub and insert clearance
Standard
3rd-4th
0.01-0.19 (0.0004-0.0075)
1st-2nd 0.09-0.31 (0.0035-0.0122) 5th
Fig. 7B-83
~ MAINSHAFT RUN-OUT
mm (in)
Limit
0.3 (0.012)
0.4 (0.016)
• Install
the mainshaft to a grinding machine.
• Use a dial indicator to measure the mainshaft
central portion run-out (Fig. 7B-84).
If the measured mainshaft run-out exceeds the
specified
limit, the mainshaft must be replaced.
Mainshaft run-out mm (in)
Limit
0.05 (0.0020)
Fig. 7B-84

Block ring
Outside..., rr-in~g-+------.=
Inside ring ,..r--+---n
Fig. 78-92
20. 1st-2nd synchronizer assembly (Fig. 78-93, Fig.
78-94)
1)
2)
3)
4)
Check that the inserts® fit snugly into the
block ring insert grooves.
Check that the inserts
springs@ are fitted
to the inserts as shown in the illustration.
Check that the clutch hub @ and the
sleeve® slide smoothly.
Install
the synchronizer assembly to the
mainshaft.
The
clutch hub face (with the heavy boss)
must be facing the 2nd gear side.
2nd gear side
Fig. 78-93
Rear
side
MANUAL TRANSMISSION 78-35
Fig. 78-94
19. Clutch hub snap ring
l'fi1 • Select the snap ring which will provide the
1..!:!1 minimum clearance between the 1st-2nd
clutch hub and the snap ring (Fig. 78-95).
There are three snap ring sizes
available.
The snap rings are color-coded to indicate their
thickness (Fig. 78-96).
Clutch hub and snap ring clearance mm (in)
Standard
0-0.1 (0-0.004)
Fig. 78-95
Fig. 78-96

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