Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 951
MANUAL TRANSMISSION
7B–39
226RW096
7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter
of the mainshaft journal.
Mea-
sure
Positio
n
Standard
A
37.984 – 38.000 mm (1.4954 – 1.4961 in)
B
46.984 – 47.000 mm (1.8498 – 1.8504 in)
C
38.979 – 38.995 mm (1.5346 – 1.5352 in)
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2. Using a micrometer, measure the mainshaft
flange thickness.
Standard: 5.0 mm (0.197 in)
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3. Install the mainshaft to V-blocks.
4. Use a dial indicator to measure the mainshaft
central portion run-out.
Standard: less than 0.015 mm (0.0006 in)
226RW097
7B–40 MANUAL TRANSMISSION
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, 3rd gear and
3rd block ring to the mainshaft.
226RW098
9. Install the clutch hub No.2.
1. Install the clutch hub No.2 and hub sleeve No.2.
NOTE: Be careful the direction of the clutch hub No.2, as
shown.
2. Using a screwdriver, install 3 inserts and 2
springs.
NOTE: Position the insert springs so that their end gaps
are not in line.
226RW099
3. Using installer J–42797 and a press, install the
clutch hub No.2 and hub sleeve No.2 to the
mainshaft.
NOTE:
D
Align the block ring slots with the inserts.
D
Check that the gear rotates smoothly.
226RW100
4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A
1.80 – 1.85 mm (0.071 – 0.073 in)
B
1.85 – 1.90 mm (0.073 – 0.075 in)
C
1.90 – 1.95 mm (0.075 – 0.077 in)
D
1.95 – 2.00 mm (0.077 – 0.079 in)
E
2.00 – 2.05 mm (0.079 – 0.081 in)
F
2.05 – 2.10 mm (0.081 – 0.083 in)
G
2.10 – 2.15 mm (0.083 – 0.085 in)
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MANUAL TRANSMISSION
7B–41
5. Using a snap ring expander, install the new snap
ring.
NOTE: Be careful not to damage the bearing surface.
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6. Using a thickness gauge, inspect the 3rd gear
thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
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10. Install the 2nd gear.
1. Install the synchronizer ring set NO.1 to the 2nd
gear.
NOTE: Align the nail of middle ring with gear spline slots.
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2. Install the needle roller bearing, 2nd gear and 2nd
gear block ring set to the mainshaft.
226RW107
7B–42 MANUAL TRANSMISSION
11. Install the clutch hub No.1.
1. Install the 3 inserts and 3 insert springs to the
clutch hub No.1.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.
226RW108
2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No.1 installing direction, as
shown.
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3. Using installer J–42798 and a press, install the
hub No.1 by retaining the reverse gear.
NOTE:
D
Align the projection of inner ring with hub No.1 slots.
D
Check that the gear rotates smoothly.
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4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A
2.30 – 2.35 mm (0.091 – 0.093 in)
B
2.35 – 2.40 mm (0.093 – 0.095 in)
C
2.40 – 2.45 mm (0.095 – 0.097 in)
D
2.45 – 2.50 mm (0.097 – 0.098 in)
E
2.50 – 2.55 mm (0.098 – 0.100 in)
F
2.55 – 2.60 mm (0.100 – 0.102 in)
G
2.60 – 2.65 mm (0.102 – 0.104 in)
226RW111
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