1995 ISUZU TROOPER Workshop Manual

(3) The cut-away portion of select rod head@
should
align with that of the rear case
hole's
stopper© (Fig. 78-25).
• Tighten the eleven transfer rear case bolts to
the specified torque.
1~1 Torque N·m (lb·ft) j 37 (27)
U7NOTE:
'({ Notes when tightening the bolt:
10.
• After cleaning the bolt hole, dry it thoroughly
with air.
• After cleaning the screw face of a removed bolt
or new one, dry it thoroughly. Apply rec­
ommended liquid gasket (LOCTITE 242) or its
equivalent before tightening it.
Fig.
78-25
Gear control box assembly
• Install a new gasket.
• Install the harness clip and then tighten four
new gear control
box bolts to the specified
torque (Fig.
78-26).
I~I_T_o_rq_u_e_N_·m_(lb_·_ft)____.l ___ 20_(_1_4) __ _
Fig. 78-26
MANUAL TRANSMISSION 78-15
9. Rear companion flange
8. Front companion flange
• Install the rear and front companion flange.
• Install the 0-ring.
IQil • Use the flange holder to tighten the flange nuts
l..::rJ to the transfer case (Fig. 78-27).
Flange holder : J-37221
• Tighten new transfer flange nuts to the
specified torque.
I~I_T_o_r-..:.q_ue ______ -. ___ N_·_m_(lb_·_ft_)
Rear companion flange 167 (123)
Front companion flange 137 (1 01)
Fig. 78-27
1®.1• Use the punch to stake the rear companion
flange
nut at two spots (Fig. 78-28, 78-29).
Punch: J-39209
• Stake the front companion flange nut at one
spot.
U7 NOTE:
'({ Be sure to confirm that there is no crack at the
staked portion
of the flange nut after staking.
Fig.
78-28

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)
..

Fig. 78-31
3. Fulcrum bridge
• Install the fulcrum bridge to the transmission
case.
• Tighten three fulcrum bridge bolts to the
specified torque (Fig. 78-32).
~~~ Torque N·m (lb·ft) J 38 (28)
Fig. 78-32
2. Shift fork (Fig. 78-33)
c:::;:]. • Apply grease to the pin hole inner circum­
D ferences and thrust surfaces.
• Attach the shift fork to the fulcrum bridge by
inserting the shift fork pin
from the bottom side
of the fulcrum bridge.
• Install the washer and snap pin.
MANUAL TRANSMISSION 78-17
Apply grease
Fig. 78-33
1. Release bearing
c:::;:] • Apply grease to the areas shown in Fig. 78-34.
D • Install the release bearing to the shift fork in the
proper direction (Fig. 78-35).
\f7 NOTE:
'V Ensure release bearing is properly positioned
during
installation, as shown in Fig. 78-35.
Apply grease
Apply grease +---+--11~
Fig. 78-34
Fig. 78-35

78-18 MANUAL TRANSMISSION
INTERMEDIATE PLATE WITH GEAR ASSEMBLY, DETENT, SHIFT ARM, AND
INTERLOCK PIN
9 10
Disassembly steps
1. Detent spring plate and gasket
2. Detent spring
3. Detent ball
4. Spring 5. Rev-5th shift rod
6. Rev-5th shift arm and reverse
inhibitor
7. 1st-2nd shift rod
8. 3rd-4th shift rod
9. 3rd-4th shift arm
10. 1st-2nd shift arm
11. Interlock pin
12. Intermediate plate and
gear assembly
12
1
~ 4
Fig. 78-36
Reassembly steps
12.
Intermediate plate and
gear assembly
10. 1st-2nd shift arm
9. 3rd-4th shift arm
8. 3rd-4th shift rod
11.
Interlock pin 7. 1st-2nd shift rod 6. Rev-5th shift arm and reverse
i11hibitor 5. Rev-5th shift rod
4. Spring 3. Detent ball 2. Detent spring
1. Detent spring plate and gasket
7
1
•

1 .. !•1 DISASSEMBL V
1. Detent spring plate and gasket
2. Detent spring
3. Detent ball
• Use a magnetic hand to remove the detent balls
from the intermediate plate (Fig. 78-37).
Fig. 78-37
4. Spring
5. Rev-5th shift rod
6. Rev-5th shift arm and reverse inhibitor
7. 1st-2nd shift rod
8. 3rd-4th shift rod
9. 3rd-4th shift arm
10. 1st-2nd shift arm
• Hold a round bar against the shift arm end (Fig.
78-38).
• Use a spring pin remover to remove the shift
arm spring pin
from the shift arm and the shift
rod (Fig. 78-39).
• Move the 3rd-4th shift rod forward (Fig. 78-40).
Take care not to lose the interlock pins.
Fig. 78-38
MANUAL TRANSMISSION 78-19
Fig. 78-39
Fig. 78-40
11. Interlock pin
• Carefully remove the reverse shifter rod
forward to avoid
losing the interlock pins.
U7 NOTE:
'YI Remove the shifter rods carefully. Interlock pins
are
located between the shifter rod in the
intermediate
plate.
12. Intermediate plate and gear assembly
[1:!) INSPECTION AND REPAIR
Make the necessary adjustments, and part
replacements
if excessive wear or damage is
discovered during inspection.
~ SHIFT ARM THICKNESS
• Use a micrometer to measure the shift arm
thickness (Fig. 78-41).
If the measured value is less than the specified
limit, the shift arm must be replaced.
Shift
arm thickness mm (in)
Standard Limit
1st-2nd 9.60-9.85
(0.378-0.388)
3rd-4th 9.0
(0.354)
Rev.5th 9.60-9.80 (0.378-0.386)