2004 ISUZU TF SERIES lock

MSG MODEL 7B-35


Important Operations
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque Nm(kgfm/lbft)
18.6 (1.9 / 13.7)



3) Set the mainshaft with gear assembly

1 and the counter
gear assembly

2 to the holding fixture
3.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the
counter shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the
counter gear ball bearings.



6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque Nm (kgfm/lbft)
107.8 (11 / 79.6)



9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse
gear side.

7B-36 MSG MODEL


13. Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer

1 and the insert short side
2
must be facing to the rear side of the transmission.


14. Mainshaft Lock Nut and Washer
1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use the lock nut wrench to tighten the lock nut to the
specified torque.
Lock Nut Wrench : 5-8840-0353-0 (J-36629)
Lock Nut Torque Nm(kgfm/lbft)
107.8 (11 / 79.6)



22. Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque N
m(kgf
m/lb
ft)
107.8 (11 / 79.6)



18. Thrust Washer and Lock Ball
23. Thrust Washer Thrust Ring
24. Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the
thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.


3) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.

7B-38 MSG MODEL
DETENT AND SHIFT ARM ASSEMBLY



Reassembly Steps
1. Intermediate plate and gear assembly


2. 1st-2nd shift arm


3. 3rd-4th shift arm
4. Interlock pin
5. 3rd-4th shift rod
6. 1st-2nd shift rod



7. Rev.-5th shift arm
8. Rev.-5th shift rod
9. Detent ball
10. Detent spring


11. Detent spring plate and gasket

7B-40 MSG MODEL
MAJOR COMPONENTS







RTW47BLF000401

Reassembly steps
1. Intermediate plate with gear assembly


2. Rear cover with oil seal


3. Transmission case


4. Bearing snap ring
5. Counter gear snap ring



6. Front cover with oil seal
7. Speedometer driven gear
8. Gear control box assembly
9. Speedpmeter sensor
10. Clutch shift fork
11. Clutch shift block and release bearing

MANUAL TRANSMISSION 7B1-1

SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (4





2)
Service Precaution .......................................................................................................... 7B1 – 3
General Description ........................................................................................................ 7B1 – 4
Rear Oil Seal (4




2) ........................................................................................................... 7B1 – 5
Transmission (4




2) ......................................................................................................... 7B1 – 7
Disassembled View ..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –12
Transmission Case .......................................................................................................... 7B1 –18
Major Component ........................................................................................................ 7B1 –18
Disassembly ................................................................................................................ 7B1 –19
Reassembly ................................................................................................................. 7B1 –20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –23
Disassembled View ..................................................................................................... 7B1 –23
Disassembly ................................................................................................................ 7B1 –24
Inspection and Repair ................................................................................................. 7B1 –25
Reassembly ................................................................................................................. 7B1 –26
Reverse Gear and 5th Gear ............................................................................................ 7B1 –27
Disassembled View ..................................................................................................... 7B1 –27
Disassembly ................................................................................................................ 7B1 –29
Inspection and Repair ................................................................................................. 7B1 –31
Reassembly ................................................................................................................. 7B1 –31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –38
Disassembled View ..................................................................................................... 7B1 –38
Disassembly ................................................................................................................ 7B1 –40
Inspection and Repair ................................................................................................. 7B1 –42
Reassembly ................................................................................................................. 7B1 –45
Main Data and Specifications ......................................................................................... 7B1 –51

7B1-2 MANUAL TRANSMISSION

Troubleshooting ............................................................................................................... 7B1 –55
Special Tools (4





2) .......................................................................................................... 7B1 –62


MUA (4





4)
Service Precaution .......................................................................................................... 7B1 –63
General Description ........................................................................................................ 7B1 –64
Transmission (4




4) ......................................................................................................... 7B1 –65
Disassembled View ..................................................................................................... 7B1 –65
Removal ....................................................................................................................... 7B1 –66
Installation ................................................................................................................... 7B1 –70
Transmission Case .......................................................................................................... 7B1 –77
Major Component ........................................................................................................ 7B1 –77
Disassembly ................................................................................................................ 7B1 –78
Reassembly ................................................................................................................. 7B1 –79
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –82
Disassembled View ..................................................................................................... 7B1 –82
Disassembly ................................................................................................................ 7B1 –83
Inspection and Repair ................................................................................................. 7B1 –83
Reassembly ................................................................................................................. 7B1 –84
Reverse Gear and 5th Gear ............................................................................................ 7B1 –85
Disassembled View ..................................................................................................... 7B1 –85
Disassembly ................................................................................................................ 7B1 –86
Inspection and Repair ................................................................................................. 7B1 –88
Reassembly ................................................................................................................. 7B1 –88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –94
Disassembled View ..................................................................................................... 7B1 –94
Disassembly ................................................................................................................ 7B1 –96
Inspection and Repair .............................................................................................. 7B1 – 98
Reassembly .............................................................................................................. 7B1 – 101
Main Data and Specifications ..................................................................................... 7B1 – 107
Troubleshooting ........................................................................................................... 7B1 – 111
Special Tools (4





4) ...................................................................................................... 7B1 – 118

MANUAL TRANSMISSION 7B1-3

Service Precaution

WARNING: THIS VEHICLE HAS 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 PERFORMING 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 fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

MANUAL TRANSMISSION 7B1-23

Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View



RTW47BLF000501
Legend

(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly