1998 ISUZU TROOPER clutch

MANUAL TRANSMISSION7B±45
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, 3rd gear and
3rd block ring to the mainshaft.
226RW098
9. Install the clutch hub No.2.
1. Install the clutch hub No.2 and hub sleeve No.2.
NOTE: Be careful the direction of the clutch hub No.2, as
shown.
2. Using a screwdriver, install 3 inserts and 2
springs.
NOTE: Position the insert springs so that their end gaps
are not in line.
226RW099
3. Using installer 5±8840±2553±0 (J±42797) and a
press, install the clutch nob No.2 and hub sleeve
No.2 to the mainshaft.NOTE:

Align the brock ring slots with the inserts.

Check that the gear rotates smoothly.
226RW206
4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A1.80 ± 1.85 mm (0.071 ± 0.073 in)
B1.85 ± 1.90 mm (0.073 ± 0.075 in)
C1.90 ± 1.95 mm (0.075 ± 0.077 in)
D1.95 ± 2.00 mm (0.077 ± 0.079 in)
E2.00 ± 2.05 mm (0.079 ± 0.081 in)
F2.05 ± 2.10 mm (0.081 ± 0.083 in)
G2.10 ± 2.15 mm (0.083 ± 0.085 in)
226RW102

MANUAL TRANSMISSION7B±47
11. Install the clutch hub No.1.
1. Install the 3 inserts and 3 insert springs to the
clutch hub No.1.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.
226RW108
2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No.1 installing direction, as
shown.
226RW109
3. Using installer 5±8840±2554±0 (J±42798) and a
press, install the hub No.1 by retaining the
reverse gear.NOTE:

Align the projection of inner ring with hub No.1 slots.

Check that the gear rotates smoothly.
226RW205
4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.30 ± 2.35 mm (0.091 ± 0.093 in)
B2.35 ± 2.40 mm (0.093 ± 0.095 in)
C2.40 ± 2.45 mm (0.095 ± 0.097 in)
D2.45 ± 2.50 mm (0.097 ± 0.098 in)
E2.50 ± 2.55 mm (0.098 ± 0.100 in)
F2.55 ± 2.60 mm (0.100 ± 0.102 in)
G2.60 ± 2.65 mm (0.102 ± 0.104 in)
226RW111

7B±66MANUAL TRANSMISSION
38. Install clutch housing.
1. Install the clutch housing to the transmission
case.
Torque: 36 N´m (3.7 kg´m/27 lb ft)
NOTE: Tighten the all bolts evenly.
241RW001
39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 N´m (4.0 kg´m/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
Torque: 44 N´m (4.5 kg´m/33 lb ft)
5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 N´m (3.8 kg´m/27 lb ft)
(4JX1)
220RW093
40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
220RW086

7B±72MANUAL TRANSMISSION
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2550±0
(J±42794)
Gear spline pieace
remover
5±8840±2551±0
(J±42795)
Center bearing remover
5±8840±2560±0
(J±42988)
Attachment
5±8840±2552±0
(J±42796)
Counter gear shaft
center bearing installer
5±8840±2553±0
(J±42797)
Clutch hub (No.2)
installer
5±8840±2554±0
(J±42798)
Clutch hub (No.1)
installer
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2555±0
(J±42799)
Installer
5±8840±2556±0
(J±42800)
Counter gear shaft front
bearing installer
5±8840±2559±0
(J±42904)
Top gear shaft front
bearing installer
5±8840±2557±0
(J±42801)
Front rerainer oil seal
installer
5±8840±2558±0
(J±42802)
Transfer adapter oil seal
installer
5±8840±0007±0
(J±8092)
Driver handle

CLUTCH7C±1
TRANSMISSION
CLUTCH
CONTENTS
Service Precaution 7C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 7C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 7C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly 7C±9. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly and Associated Parts 7C±9. . .
Removal 7C±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C±10. . . . . . . . . . . . . . . . . .
Installation 7C±15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control 7C±17. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control Parts 7C±17. . . . . . . . . . . . . . . . . . .
Removal 7C±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C±18. . . . . . . . . . . . . . . . . .
Installation 7C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 7C±19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 7C±22. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C±22. . . . . . . . . . . . . . . . . . . .
Disassembly 7C±23. . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 7C±23. . . . . . . . . . . . . . . . . .
Reassembly 7C±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Slave Cylinder 7C±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C±24. . . . . . . . . . . . . . . . . . . .
Disassembly 7C±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C±24. . . . . . . . . . . . . . . . . .
Reassembly 7C±25. . . . . . . . . . . . . . . . . . . . . . . . . .
Damper Cylinder 7C±26. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C±26. . . . . . . . . . . . . . . . . . . .
Disassembly 7C±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C±26. . . . . . . . . . . . . . . . . .
Reassembly 7C±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 7C±27. . . . . . . . . . . . .
General Specifications 7C±27. . . . . . . . . . . . . . . . .
Torque Specifications 7C±27. . . . . . . . . . . . . . . . . .
Special Tools 7C±30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFOMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastner in the
proper location. When you reolace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that requir a
replacement after removal. ISUZU will also call out
the fasteners that requir thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fastners or fastner
joint interfaces. Generally,such coatings adversely
affect the fastner torque and the joint clamping force,
and may damage the fastner. When you install
fasteners, use the correct tightening sequence and
specifications. Following these instructions can
help you avoid damage to parts and systems.

CLUTCH7C±3
Master Cylinder
(6VE1 LHD)
A07RW007
(6VE1 RHD)
A07RW066

7C±4CLUTCH
(4JX1)
A07RW067
Damper Cylinder
(Except 6VE1 LHD)
A07RS004
In order to reduce the occurrence of noises at the clutch
hydraulic system, the damper cylinder is used in theclutch hydraulic line between the master cylinder and
slave cylinder.

CLUTCH7C±5
Slave Cylinder
A07RS005
Pressure Plate Assembly
A07RS006