1995 ISUZU TROOPER Workshop Manual

AUTOMATIC TRAN
INTERNAL
COM SMISSION (4L30-E)
------P--O~N~E~N~TIS ~ 7A-217
Fig. 7 A~-~10:022---------

7A-218 AUTOMATIC TRANSMISSION (4L30-E}
608 Seal, reverse clutch piston (inner)
609 Seal, reverse clutch piston (outer)
610 Piston, reverse clutch 611 Spring, piston clutch 612 Seat, spring/reverse clutch 613 Ring, Retaining
614
Plate, waved/reverse clutch 615 Plate, reverse clutch (steel) 616 Plate assembly, reverse clutch (lined)
617 Plate, reverse clutch pressure/selective
618 Drum assembly, 2nd clutch
620 Seal, 2nd clutch piston (Inner) 621 Seal, 2nd clutch piston (Outer) 622 Piston, 2nd clutch
623 Seat, spring/2nd clutch 625 Plate, waved/2nd clutch 626 Plate, 2nd clutch (Steel)
627 Plate assembly, 2nd clutch (Lined)
628 Spacer, 2nd clutch 629 Ring, retaining
630 Gear, ring 631 Washer, thrust/2nd clutch/3rd clutch 632 Thrust washer, clutch hub
634 Drum assembly, 3rd clutch
635 Seal, 3rd clutch piston (Inner) 636 Washer, retaining
637 Seal, 3rd clutch piston (Outer)
INTERNAL COMPONENTS
638 Piston 3rd clutch 639 Seat, spring/3rd clutch
640 Ring, n~taining 641 Plate, spring cushion/3rd clutch 642 Plate, :::rd clutch (Steel) 643 Plate assembly, 3rd clutch (Lined)
644 Washer,
thrust/input sun
645 Bearino, input shaft/gear assembly 646 Gear assembly, input sun
647
Race assembly, sprag
648 Ring, mtaining/sprag
649 Ring,
mtaining 650 Cage a:;sembly, sprag 651 Bearinn, output shaft/input sun
652 Washer, output shaft/input sun
653 Carrier assembly, planetary 658 Gear, reaction sun
659 Drum, 1·eaction sun
664 Band
assembly, brake 667 Seal, ring/wheel parking lock 668 Wheel, parking lock
672 Wheel, speedo
673 Ring, rEttaining
675
Bearin~1. thrust assembly
CENTER SUPPORT ASSEMBLY
701
Fig. 7A-103
701 Center support 702 Retainer plate
703 Plug, lockout
704 Spring,
overrun lockout
705 Valve,
overrun lockout
•

MANUAL TRANSMISSION 78-1
SECTION 78
MANUAL TRANSMISSION
w CAUTION
When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs
to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound, will be called out. The correct torque
values must be used when installing fasteners that require torque. If the above conditions are not followed,
parts or system damage could result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . 78-1
Construction . . . . . . . . . . . . . . . . . . . . . . . . . 78-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-3
On-Vehicle Service ..................... 78-4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . 78-4
Gear Control Box Assembly . . . . . . . . . . . 78-10
Unit Repair ........................... 78-12
Transmission Case And Transfer
Case .............................. 78-12
Intermediate Plate With Gear Assembly
Detent, Shift Arm, And Interlock Pin ... 78-18
Reverse Gear
And 5th Gear ............ 78-22
Top Gear Shaft, Main Gear Shaft
And Counter Gear Shaft .............. 78-29
Main Data And Specifications ............ 78-39
General Specifications ................ 78-39
Torque Specifications ................ 78-40
Special
Tools .......................... 78-43
GENERAL DESCRIPTION
The MUA5C is a constant mesh transmission,
synchronized in
all speeds. The transmission is
designed
for ease of shifting and the quietest possible
operation.
Principle parts of the transmission are the integral
clutch
housing, intermediate plate, the transfer case,
the rear cover, and the gears.
The transmission
control box and transfer control box
are
built into the transfer case.

78-2 MANUAL TRANSMISSION
CONSTRUCTION
Manual transmission
Transfer case
Fig. 78-1
Ill

MANUAL TRANSMISSION 78-3
DIAGNOSIS
Problem Possible cause Correction
•
Flywheel pilot bearing worn Replace
•
Bearings worn or broken (Mainshaft, counter shaft, and Replace
transfer shaft)
Abnormal noise • Gear tooth contact surfaces worn or scuffed (Mainshaft, Replace
counter shaft, reverse idler gear and transfer gears)
• Splines worn (Mainshaft, synchronizer clutch hub) Replace
•
Gear or bearing thrust face seized Replace
•
Lack of backlash between meshing gears Replace
• Improper clutch pedal
free play Readjust
• Change lever sliding portions worn Repair or replace
Regrease
• Shift block, shift rod and/or control box sliding faces Replace
Hard Shifting worn
• Shift arm and synchronizer sleeve groove worn Replace worn parts
• Thrust washer, collar, and/or gear thrust faces worn Replace worn parts
(Mainshaft and counter shaft thrust
play)
•
Synchronizer parts worn Replace
•
Detent ball worn Replace
•
Detent spring weakened or broken Replace
Walking
or • Shift rod and/or control box sliding faces worn Replace
Jumping out of • Shift arm and synchronizer sleeve groove worn Replace worn parts
gear
• Thrust washer, collar, and/or gear thrust faces worn Replace worn parts
(Mainshaft and counter shaft thrust
play)
•
Bearings worn or broken Replace
• Splines
worn (Mainshaft, synchronizer hub) Replace
•
Synchronizer spring weakened or broken Replace
•
Loose drain plug(s) and/or filler plug(s) Tighten
Oil leakage Replenish
oil
• Defective or improperly installed gasket(s) Replace
• Oil seal
worn or scratched Replace

78-4 MANUAL TRANSMISSION
ON-VEHICLE SERVICE
TRANSMISSION
10
~··
v
"
9
r 12 5
3
5
3
2
1
Removal steps
1. Exhaust and transfer protectors
7. 3rd crossmember
2. Exhaust pipe and heat protector 8. Engine rear mount 3. Slave cylinder, .heat protector,
9. Front crossmember dust cover ( 1) and (2) 10. Front propeller shaft
4. Rear propeller shaft
11. Gear control lever 5. Transmission harness connectors
12. Flywheel under cover bolts 6. Engine rear mount nuts
13. Transmission assembly
Fig. 78-2
(a
11
t
.__J
7
[J
4
Installation steps To install,
follow the removal steps in the reverse order.
•

EJ REMOVAL
Preparation:
'--"' • Remove engine hood.
• Disconnect battery negative(-) cable.
1. Exhaust and transfer protectors
• Remove three exhaust and transfer protectors.
2. Exhaust pipe and heat protector
3.
• Disconnect oxygen sensor connector from the
transmission harness (Fig. 78-3).
• Remove the center and left front exhaust pipe.
• Remove the harness heat protector.
lj
Fig. 78-3
Slave cylinder, heat protector, dust cover (1)
and (2) (Fig. 78-4)
• Remove the heat protector.
• Remove the slave cylinder.
•
Remove the dust cover (1) and (2).
4. Rear propeller shaft
• Remove the rear propeller shaft (Fig. 78-5).
W NOTE:
Apply alignment marks on the flange at the both
front and rear side.
Fig. 78-4
MANUAL TRANSMISSION 78-5
Fig. 78-5
5. Transmission harness connectors
• Disconnect the reverse lamp switch, 4WD
indicator switch,
1-2 and 3-4 indicator switch
harness connectors.
• Disconnect the speed sensor harness
connector (Fig. 78-6).
• Remove two transmission harness clamps
from the transmission case and bracket (Fig.
78-7).
Fig. 78-6
Fig. 78-7