1995 ISUZU TROOPER Workshop Manual

Release bearing disconnection
(Fig. 7B-12a & 7B-12b)
CD Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
® Insert the clutch release bearing remover
between the
wedge collar and the release
bearing.
® Turn the remover to separate the release
bearing.
IDNOTE:
Yl Be sure not to insert the remover between the
wedge collar and the clutch.
Fig. 7B-12a
MANUAL TRANSMISSION 78-7
Fig. 7B-12b
• Remove the transmission retaining nuts and
bolts.
•
Remove the transmission from the vehicle.
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
13. Transmission assembly
r;:::;J • Apply a thin coat of molybdenum disulfide
D grease to the top gear shaft spline.
• 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.
• Align the top gear shaft spline with the clutch
driven plate spline (Fig. 78-13).
• Install the transmission to the engine.
Tighten the transmission nuts and
bolts (Fig.
78-14).
Fig. 78-13

78-8 MANUAL TRANSMISSION
45
Fig. 78-14
• Apply a force of 59-78N (13.2 -17.61b) to the tip
of the shift fork in the direction of the
transmission
to engage the clutch pressure
plate and release bearing (Fig. 78-15).
W NOTE:
A click 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 25N (5.5 I b). If the
shift fork
will not move, then they are securely
engaged.
45 ~ Torque : N·m/lb·ft
Length: mm
Fig. 78-15
..

12. Flywheel under cover bolts
• Install
three flywheel under cover bolts.
11. Gear control lever
• Install
the transmission control lever and
transfer
control lever.
• Install
the grommet assembly.
• Install
the front console assembly.
• Install
the gear control lever knob.
• Support the transfer case with a jack and then
remove the transmission jack
from
transmission side.
10. Front propeller shaft
• Install the front propeller shaft.
~~~ Torque N·m (lb·ft) 63 (46)
9. Front crossmember
• Install the front crossmember.
~~~ Torque N·m (lb·ft) 78 (58)
8. Engine rear mount
• Install the engine rear mount.
~~~ Torque N·m (lb·ft) 41 (30)
7. 3rd crossmember
• Install the 3rd crossmember.
1~1 Torque N-m (lb·ft) 50 (37)
6. Engine rear mount nuts
~~~ Torque N-m (lb·ft) 50 (37)
• Remove the transmission jack.
5. Transmission harness connectors
• Install bracket and two transmission harness
clamps to the transmission case (Fig. 78-15a).
• Connect the speed sensor harness connector.
• Connect the reverse lamp switch, 4WD
indicator
switch, 1-2 and 3-4 indicator switch
harness connectors.
Fig. 78-15a
MANUAL TRANSMISSION 78-9
4. Rear propeller shaft
• Install the rear propeller shaft.
I~I __ T_o_rq~u_e __ N_·m~(_lb_·ft~)~ _____ 6_3~(_46~) ____ _
3. Slave cylinder. heat protector. dust cover (1)
and (2) (Fig. 78-16)
• Apply the grease to top hole portion of the shift
fork.
• Install the slave cylinder.
~~~ Torque N·m (lb·ft) I 43 (32) _..:....__~----
• Install the clutch dust cover (1) and (2) to the
clutch housing.
~~~ Torque N·m (lb·in) 6 (52)
Apply grease
Fig. 78-16
• Install the slave cylinder heat protector to the
slave cylinder.
2. Exhaust pipe and heat protector
• Install the harness heat protector.
• Install the center and left front exhaust pipes.
~~~ Torque
Exh.pipe-exh.manifold
Center pipe
flange bolt N·m
(lb·ft)
67 (49)
43 (32)
• Connect oxygen sensor connector to the
transmission harness.
1. Exhaust and transfer protectors
~~~ Torque N·m (lb·ft) 37 (27)
• Connect battery negative (-) cable.
• Install
engine hood.

78-10 MANUAL TRANSMISSION
GEAR CONTROL BOX ASSEMBLY
l••l REMOVAL
Preparation:
• Disconnect battery negative (-) cable.
1. Knob
• Remove knobs of the transmission control
lever
and transfer control lever.
2. Front console assembly
• Remove front console assembly.
•
Disconnect harness connector.
• Remove rear heater duct.
3. Grommet assembly
• Remove grommet assembly.
4. Transmission control lever and transfer control
lever
• Remove transmission control lever and
transfer
control lever.
5. Gear control box assembly (Fig. 7B-16a)
• Disconnect neutral switch harness connector.
• Remove neutral switch.
• Remove four gear control box bolts and
harness
clips.
•
Remove gear control box assembly and gasket
from the transmission case.
Fig. 7B-16a
l••l INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
5. Gear control box assembly
• Install a new gasket.
• Install four harness clips and then tighten four
new control box bolts to the specified torque
(Fig. 7B-16b).
1~1 Torque N·m (lb·ft) 20 (14)
Fig. 7B-16b
• Install neutral switch and connect harness
connector.
4.
Transmission control lever and transfer control
lever
• Install transmission control lever and transfer
control lever.
3. Grommet assembly
• Install grommet assembly.
2. Front console assembly
• Install rear heater duct.
• Conne,ct harness connector.
• Install front console assembly.
1. Knob
• Install knobs of the transmission control lever
and transfer control lever.
• Conne·ct
battery negative (-) cable.
•

MANUAL TRANSMISSION 78-11
MEMO
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