2004 ISUZU TF SERIES manual transmission

7B1-96 MANUAL TRANSMISSION

Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the ball bearing(3).
226RW216
4. Remove needle bearing (4) and top block ring (5),
mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the
mainshaft snap ring (6).

226RS008

6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
Disassemble the synchronizer assembly.
226RW217

Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
8. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RW218

MANUAL TRANSMISSION 7B1-97

9.Disassemble 1st inside ring (15), 1st outside ring (16),
and 1st block ring (17).
10.Remove needle bearing (18).
11.Use a pair of snap ring pliers to remove the clutch
hub snap ring (19).

226RS031
12.Use bench press and the bearing remover 5-8840-
0015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
Disassemble the synchronizer assembly.
226RW220

Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
13. Remove needle bearing (25) from mainshaft (26).
14. Remove bearing snap ring (27).
15. Remove the front roller bearing (28) by performing
the following steps.


Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.

Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RW219
16. Remove center roller bearing (29) from counter gear
shaft (30).

7B1-98 MANUAL TRANSMISSION

Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Block Ring and Dog Teeth Clearance

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS035
If the measured value exceeds the specified limit,
the block ring must be replaced.

Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)

MANUAL TRANSMISSION 7B1-99

1st-2nd Synchronizer (3-CONE)

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.

Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance


Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.

226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.158 in)
1st-2nd3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)

Clutch Hub and Insert Clearance


Use a thickness gauge to measure the clearance
between the clutch hub and the insert.

226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.

Clutch Hub and Insert Clearance
Standard Limit
1st-2nd
3rd-4th 0.01 – 0.21 mm
(0.004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)

7B1-100 MANUAL TRANSMISSION

Mainshaft Run-out

Install the mainshaft to V-blocks.


Use a dial indicator to measure the mainshaft
central portion run-out.

226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter


Use an inside dial indicator to measure the gear
inside diameter.

226RS040
If the measured value is less than the specified limit,
the gear must be replace.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance


Use a micrometer to measure the idler gear shaft
diameter.

Use an inside dial indicator to measure the idler
gear inside diameter.

226RS041


Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)

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 7B1-103





266RS049
7. Install the synchronizer assembly (20) to the
mainshaft (26).
The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.

226RS048
8. Install clutch hub snap ring(19) by performing the
following steps:


Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring.




226RS050

There are three snap ring sizes available.

The snap rings are color coded to indicate their
thickness as shown in the figure.

226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)

Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue

Use a pair of snap ring pliers to install the snap
ring (19) to the mainshaft (26).
The snap ring must be fully inserted into the
mainshaft snap ring groove.