2004 ISUZU TF SERIES Workshop Manual

Page 3249 of 4264

ISUZU TF SERIES 2004  Workshop Manual MANUAL TRANSMISSION     7B1-85
 
Reverse Gear and 5th Gear 
Disassembled View 
 226R300024 
 
Legend
 
(1)  Collar Snap Ring  (15) Counter 5th Gear 
(2)  Oil Seal Collar  (16) Counter Reverse Gear 
(3

Page 3250 of 4264

ISUZU TF SERIES 2004  Workshop Manual 7B1-86     MANUAL TRANSMISSION
 
Disassembly 
  1. Use a pair of snap ring pliers to remove the collar 
snap ring (1). 
  2. Set the retaining ring remover 5-8840-2158-0 and 
puller 5-8840-2027-0 to t

Page 3251 of 4264

ISUZU TF SERIES 2004  Workshop Manual MANUAL TRANSMISSION     7B1-87
 
 11. Remove 5th gear (17), 5th block ring (18), and 
needle bearing (2 piece type) (19). 
  
226RS007
 12. Remove the mainshaft nut (20) according to 
following steps.

Page 3252 of 4264

ISUZU TF SERIES 2004  Workshop Manual 7B1-88     MANUAL TRANSMISSION
 
 13. Use screw drivers between the reverse gear (23) 
and bearing plate (25) to remove the Rev-5th 
synchronizer assembly (21) together with reverse 
block ring (22) a

Page 3253 of 4264

ISUZU TF SERIES 2004  Workshop Manual MANUAL TRANSMISSION     7B1-89
 
  2. Install bearing snap ring (26). 
  3. Apply recommended thread locking agents 
(LOCTITE 242) or its equivalent to each of the 
bearing plate screw threads. 
Insta

Page 3254 of 4264

ISUZU TF SERIES 2004  Workshop Manual 7B1-90     MANUAL TRANSMISSION
 
  6. Mesh the 1st-2nd and 3rd-4th synchronizers with 
both the 1st and 3rd gears (double engagement). 
  
226RS015
This will prevent the mainshaft from turning. 
  7.

Page 3255 of 4264

ISUZU TF SERIES 2004  Workshop Manual MANUAL TRANSMISSION     7B1-91
 
 11. Install the counter 5th gear (15) to the counter shaft.
  
226RS019
 12. Install ball bearing (14) and bearing snap ring (13) 
by performing the following steps:

Page 3256 of 4264

ISUZU TF SERIES 2004  Workshop Manual 7B1-92     MANUAL TRANSMISSION
 
14. Select reverse idler gear snap ring (7) which will 
provide the minimum clearance between the 
intermediate plate (27) and the snap ring (7). 
  
226RS022

  Ther