Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 1592
7B–4
MANUAL TRANSMISSION
Diagnosis
Condition
Possible cause
Correction
Abnormal noise
Flywheel pilot bearing worn
Replace
Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)
Replace
Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Replace
Splines worn (Mainshaft,
synchronizer clutch hub)
Replace
Gear or bearing thrust face seized
Replace
Lack of backlash between meshing
gears
Replace
Hard Shifting
Improper clutch pedal free play
Readjust
Change lever sliding portions worn
Repair or replace Regrease
Shift block, shift rod and/or control
box sliding faces worn
Replace
Shift arm and synchronizer sleeve
groove worn
Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Synchronizer parts worn
Replace
Walking or Jumping out of gear
Detent ball worn
Replace
Detent spring weakened or broken
Replace
Shift rod and/or control box sliding
faces worn
Replace
Shift arm and synchronizer sleeve
groove worn
Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Bearings worn or broken
Replace
Splines worn (Mainshaft,
synchronizer hub)
Replace
Synchronizer spring weakened or
broken
Replace
Oil leakage
Loose drain plug(s) and/or filler
plug(s)
Tighten Replenish oil
Defective or improperly installed
gasket(s)
Replace
Oil seal worn or scratched
Replace
MANUAL TRANSMISSION
7B–5
Rear Oil Seal (4X2)
Disassembled View
220RY00016
Legend
(1) Rear Propeller Shaft
(2) Rear Oil Seal
Removal
1. Raise and support vehicle with suitable jack stands.
2. Remove propeller shaft flange yoke bolts and nuts at
the differential side.
Remove propeller shaft from the transmission main
shaft spline.
3. Use a screwdriver to pry the rear oil seal from the rear
cover.
Installation
1. Install a new oil seal(2) or (3) using the installer
J–29769.
220RS044
2. Insert the splined yoke into the transmission
mainshaft spline.
3. Install the propeller shaft flange yoke to the drive
pinion flange.
Torque: 63 N·m (46 lb ft)
4. Check transmission fluid level.
5. Lower vehicle.
7B–6
MANUAL TRANSMISSION
Transmission
Disassembled View
220RW040
Legend
(1) Gear Control Lever Knob
(2) Transfer Control Lever Knob
(3) Center Console
(4) Grommet Assembly
(5) Gear Control Lever and Transfer Control Lever
(6) Transfer Protector
(7) Fairing Plate
(8) Rear Propeller Shaft
(9) Front Propeller Shaft
(10) Center Exhaust Pipe
(11) Fuel Pipe Heat Protector
(12) Harness Clamp
(13) Harness Heat Protector
(14) Slave Cylinder
(15) Dust Cover
(16) Rear Mount Nut
(17) Third Crossmember
(18) Starter
(19) Flywheel Undercover
(20) Transmission Retaining Nut and Bolt
(21) Transmission
MANUAL TRANSMISSION
7B–7
Removal
NOTE: Befor removing transmission assembly(4X4)
from vehicle, change the transfar mode to 2WD using the
4WD push button on dash panel.
1. Disconnect battery ground cable.
2. Remove gear control lever knob(1).
3. Remove transfer control lever knob(2) (4X4).
4. Remove lower cluster assembly.
740RW021
5. Remove rear console.
256RW005
6. Remove center console(3).
F07RW023
7. Remove grommet assembly(4).
262RW027
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