engine ISUZU TROOPER 1998 Service Repair Manual

MANUAL TRANSMISSION7B±11
220RW119
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
30. Remove the transmission retaining nuts and bolts.
31. Remove the transmission assembly with transfer
case from the vehicle.
NOTE: Remove the transfer case from the transmission
assembly if the transmission disassembly required.
Refer to Transfer Case in Drive Line/Axle section.
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 spline with the clutch driven
plate spline.
220RS005
4. Install the transmission to the engine.
Tighten the transmission retaining nuts and bolts.

MANUAL TRANSMISSION7B±13
(4JX1)
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5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).

7B±14MANUAL TRANSMISSION
7. Install the engine rear mount to the transmission case
and tighten the fixing bolts specified torque (6VE1).
Torque: 41 N´m (4.2kg´m/30 Ib ft)
8. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
Torque: 50 N´m (5.1kg´m/37 Ib ft)
9. Tighten the engine rear mount nuts specified torque.
Torque: 50 N´m (5.1kg´m/37 Ib ft)
10. Remove the transmission jack.
11. Apply the grease to top hole portion of the shift fork.
12. Install the slave cylinder and tighten the fixing bolts
specified torque.
Torque: 43 N´m (4.4kg´m/32 Ib ft)
13. Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
Torque: 8 N´m (0.8kg´m/69 Ib in)
220RS007
14. Install the slave cylinder heat protector to the slave
cylinder.
15. Install bracket and two transmission harness clamps
to the transmission case (6VE1).
16. Install harness heat protector (6VE1).(6VE1)
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17. Install four fuel pipe bracket (6VE1).

7B±16MANUAL TRANSMISSION
19. Connect the backup lamp switch, 4WD indicator
switch, and 1-2 indicator switch harness connectors.
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20. Install the front and 3 way exhaust pipe (6VE1).
Install the exhaust pipe with catalytic converter
(4JX1).
Torque:
Exhaust pipe to exhaust manifold:
67 N´m (6.8 kg´m/49 Ib ft)
Exhaust pipe flange bolt:
43 N´m (4.4 kg´m/32 Ib ft)
(4JX1)
150RW041
21. Connect two oxygen sensor connectors to the
transmission harness (6VE1).
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 N´m (6.4 kg´m/46 Ib ft)
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 N´m (6.4 kg´m/46 Ib ft)24. Install transfer protector and tighten the fixing bolts
specified torque.
Torque: 37 N´m (3.8 kg´m/27 Ib ft)
25. Install the transmission control lever and transfer
control lever.
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26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
29. Connect battery ground cable.
30. Install engine hood.

7B±42MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance
between the 4th block ring back and gear spline
end.
Standard: 0.75 ± 1.65 mm (0.030 ± 0.065 in)
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6. Check the braking effect of the block ring. Turn
the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
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7. Install the needle roller bearing.
2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.3. Inspect block ring
1. Using a thickness gauge, measure the clearance
between the synchronizer ring back and gear
spline end.
Gear
Standard Clearanse
1st0.80 ± 1.60 mm (0.032 ± 0.063 in)
2nd0.65 ± 1.75 mm (0.026 ± 0.069 in)
3rd0.75 ± 1.65 mm (0.030 ± 0.065 in)
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2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
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7B±68MANUAL TRANSMISSION
Main Data and Specifications
General Specifications
Transmission typeFully synchronized forward and reverse gears
Control methodDirect control with the gear shift lever on the floor
Gear ratio1st3.954
2nd2.330
3rd1.436
4th1.000
5th0.788
Rev3.918
Oil capacity lit (US qt)2.7 (2.86)
Type of lubricantEngine oil : Refer to the chart in ªSECTION 0º

MUA MODEL 7B1 – 51
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives
you important points as well as the order of operation. Be sure that you understand everything in this
Section before you begin.
Important Operations – Removal
Battery Cable
Disconnect the negative (–) cable from the battery
terminal.
Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood.
Gear Shift Lever and Transfer Change Lever
1. Place the gear shift lever in the neutral position.
2. Place the transfer change lever in the “H” position.
3. Remove the gear shift lever knob and transfer
change lever konb.
4. Remove the center console assembly and front
console assembly.
5. Remove the grommet and dust cover.
6. Remove the gear shift lever cover bolt.
7. Remove the gear shift lever.
8. Remove the transfer change lever retainer bolts.
9. Remove the transfer change lever and O-ring.
Note:
Cover the shift lever and change lever holes to prevent
the entry of foreign material into the transmission.
Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.
Transfer Case Protector (Except 00 Year or Subsequent
ones)
Remove the transfer case protector from the transmission
mounting member and the side member.
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MUA MODEL 7B1 – 53
Front Propeller Shaft
Remove the splined yoke flange bolt at the transfer case
side.
Do not allow the splined yoke to fall away from the front
propeller shaft.
If the splined yoke should fall away from the front
propeller shaft, align the setting marks
3on the splined
yoke 1and the propeller shaft 2to reassemble the two
parts.
The setting marks 3are punched circles approximately 3
mm (0.12 in) in diameter.
TDC Sensor (4JA1TC Model)
Disconnect the TDC sensor from the transmission
housing.
Harness Connector
Disconnect the 4WD switch connectors, back up light
switch connector and the speedometer sensor connector.
220R200001
Slave Cylinder
Remove the slave cylinder from the transmission case.
220LV019
Engine LIfting Hanger
1. Attach the engine lifting hanger to the front portion of
the engine.
2. Attach the lifting wire to both ends of the engine
lifting hange.

MUA MODEL 7B1 – 57
Starter Motor
1. Install the starter motor to the engine rear plate.
Starter Motor Bolt Torque kg·m (lb·ft/N·m)
8.0 ± 1.6 (58 ± 12/78 ± 16)
Engine Rear Mounting and Mounting Member
1. Install the engine rear mounting to the transmission.
Rear Mounting Bolt Torque kg·m (lb·ft/N·m)
4.2 ± 0.5 (30 ± 3.6/41 ± 4.9)
2. Install the mounting member 1to the mounting
rubber 2.
Mounting Rubber Nut Torque kg·m (lb·ft/N·m)
5.1 ± 0.6 (37 ± 4.3/50 ± 6)
3. Install the mounting member to the sidemembers.
Mounting Member Bolt Torque kg·m (lb·ft/N·m)
5.1 ± 0.6 (37 ± 4.3/50 ± 6)
Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque kg·m (lb·ft/N·m)
4.1 ± 1.0 (30 ± 7.2/40 ± 10)
Harness Connector
Disconnect the 4WD switch connectors back up light
switch connector and speedometer sensor connector.
220LV019
TDC Sensor (4JA1TC Model)
Connect the TDC sensor from the transmission housing.
220R200001

MUA MODEL 7B1 – 59
Exhaust Pipe
1. Connect the front exhaust pipe and 2nd-3rd exhaust
pipe.
2. Install the exhaust pipe bracket to the transmission
case.
220LV018
Transfer Case Protector (Except 00 Year or Subsequent
ones)
1. Install the transfer case protector 1to the mounting
member 2and the sidemebers 3.
2. Tighten the transfer case protector bolts to the
specified torque.
Transfer Case Protector Bolt Torque kg·m (lb·ft/N·m)
3.7 ± 1.0 (26.8 ± 7.2/36.3 ± 9.8)
Gear Shift Lever and Transfer Change Lever
1. Replenish the transmission case and the transfer
case with the specified engine oil.
Transmission and Transfer Case Oil lit (US/UK qt.)
Transmission Case 2.95 (3.12/2.6)
Transfer Case 1.45 (1.53/1.28)
2. Install the gear shift lever to the gear control box.
Shift Lever Cover Bolt Torque kg·m (lb·ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96)
3. Install the dust cover.
4. Insert the transfer change lever to the transfer case.
Change Lever Retainer Bolt Torque kg·m (lb·ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96)
5. Install the grommet.
6. Install the front console assembly and center console
assembly.
7. Install the gear shift lever and the transfer change
lever knobs.
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