2004 ISUZU TF SERIES check engine

MANUAL TRANSMISSION 7B1-45



Use bearing installer 5-8840-2194-0 to install the
ring.


RTW47BSH000501

Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install bearing snap ring (27) to counter gear shaft
(30).
4. Apply engine oil to the needle bearing (25) and the
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24)
to the mainshaft (26).
The 2nd gear (24) dog teeth must be facing the
transmission rear side.

226RS046

5. Assemble 2nd inside ring (23), 2nd outside ring (22),
and 2nd block ring (21) on 2nd gear (24).


Apply engine oil to the synchronizer ring friction
surfaces.

226RS047

Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by
performing the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub (5) insert grooves.
2. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.

7B1-48 MANUAL TRANSMISSION

12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.

226RS056
13. Install 3rd block ring (8).
14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the 3rd gear side.

226RW221

226RS049
15. Select and install mainshaft snap ring(6) in the
following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.

226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.

MANUAL TRANSMISSION 7B1-55

2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)Worn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)Worn, chipped, or cracked
gear(s)
NG NG NG NG OK
OK
OK OK
Gear oil (Metallic rattling)

7B1-56 MANUAL TRANSMISSION

2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OKNG NG NG NG
OK OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxWorn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG NG
OKShift block sleeve movement

7B1-72 MANUAL TRANSMISSION




RTW37BLF000201

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. (6VE1 only)
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

MANUAL TRANSMISSION 7B1-101

Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.

226RS042


Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.

Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play


Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)




226RS043

Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).


Apply engine oil to the bearing inner and outer
circumferences.


Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.

226RS044
2. Install front roller bearing (28) by performing the
following steps.


Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).


Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.

7B1-102 MANUAL TRANSMISSION



Use bearing installer 5-8840-2194-0 to install the
ring.



226RS045

Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install bearing snap ring (27) to counter gear shaft
(30).
4. Apply engine oil to the needle bearing (25) and the
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24)
to the mainshaft (26).
The 2nd gear (24) dog teeth must be facing the
transmission rear side.

226RS046

5. Assemble 2nd inside ring (23), 2nd outside ring (22),
and 2nd block ring (21).


Apply engine oil to the synchronizer ring friction
surfaces.

226RS047

Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by
performing the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub (5) insert grooves.
2. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.

MANUAL TRANSMISSION 7B1-105

12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.

226RS056
13. Install 3rd block ring (8).
14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the 3rd gear side.

226RW221

226RS049
15. Select and install mainshaft snap ring(6) in the
following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.

226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.