Isuzu N-Series. Service manual — part 804
SERVICE INFORMATION 00-1
MANUAL TRANSMISSION AND CLUTCH
MSB SERIES
SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING . . . . . . . . . . .. 00-2
Transmission . . . . . . . . . . . . . . 00-2
Clutch . . . . . . . . . . . . . . . . 00-3
MAIN DATA AND SPECIFICATIONS . . . . ... 00-4
SERVICE STANDARD. . . . . . . . . . .. 00-5
Transmission . . . . . . . . . . . . . . 00-5
Clutch . . . . . . . . . . . . . . . . 00-6
SERVICING . . . . . . . . . . . . . . .. 00-7
FIXING TORQUE. . . . . . . . . . . . 00-12
Transmission . . . . . . . . . . . . ... 00-12
Clutch . . . . . . . . . . . . . . . .. 00-13
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Transmission
PROBLEM
POSSIBLE CAUSE
CORRECTION
Abnormal Noise
1. Flywheel pilot bearing worn.
1. Replace.
2. Bearing worn or broken (Main shaft or
counter shaft).
2. Repair or replace.
3. Anti-lash plate malfunction.
3. Repair or replace.
4. Gear tooth contact surface worn or
scuffed (Main shaft, counter shaft and/
or reverse idle gear).
4. Repair or replace.
5. Spline worn (Synchronizer clutch hub).
5. Replace.
6. Gear, clutch hub or thrust washer thrust
face seized.
6. Replace.
7. Lack of backlash between mating
gears.
7. Replace.
Hard Shifting
1. Improper church pedal free play.
1. Readjust.
2. Wrong oil in use.
2. Replace with recommended oil.
3. Gear control linkage misadjust.
3. Readjust.
4. Change lever sliding portions worn.
4. Repair or replace.
5. Shift block, shift rod and/or control box
sliding faces worn.
5. Repair or replace.
6. Shift arm and/or synchronizer sleeve
groove worn.
6. Replace.
7. Synchronizer parts worn or weakened.
7. Replace.
8. Thrust washer, collar, and/or gear
thrust faces worn (Main shaft and/or
counter shaft thrust play).
8. Replace.
Walking or Jumping out
of Gear
1. Gear control linkage misadjust.
1. Readjust.
2. Detent spring weakened or broken.
2. Replace.
3. Detent ball worn.
3. Replace.
4. Change lever sliding portions worn.
4. Repair or replace.
5. Shift block, shift rod and/or control box
sliding faces worn.
5. Repair or replace.
6. Shift arm and/or synchronizer sleeve
groove worn.
6. Replace.
7. Synchronizer parts worn or weakened.
7. Replace.
8. Thrust washer, collar, and/or gear
thrust faces worn (Main shaft and/or
counter shaft thrust play).
8. Replace.
9. Spline worn (Synchronizer hub).
9. Replace.
10. Bearings worn or broken.
10. Replace.
SERVICE INFORMATION 00-3
Clutch
PROBLEM
POSSIBLE CAUSE
CORRECTION
Dragging
1. Hydraulic line leakage.
1. Repair.
2. Air in line.
2. Bleed and check for damage.
3. Master cylinder and/or slave cylinder
piston cup worn.
3. Replace.
4. Driven plate worn or warped.
4. Replace driven plate.
5. Diaphragm spring weak or tip of finger
worn.
5. Replace pressure plate assembly.
6. Driven plate sticking on spline.
6. Clean and free spline and lubricate with
grease.
7. Release bearing worn or damaged.
7. Replace release bearing.
8. Clutch pedal excessive free play.
8. Readjust.
Slipping
1. Driven plate facing worn or oil soaked.
1. Replace driven plate and check for
leaks as needed.
2. Diaphragm spring weak.
2. Replace pressure plate assembly.
3. Pressure plate and/or flywheel warped.
3. Repair or replace.
4. Clutch pedal lack of free play.
4. Readjust.
Shudder
(Chattering)
1. Engine mounting loose or broken.
1. Tighten or replace.
2. Driven plate facing warped.
2. Replace driven plate.
3. Driven plate surface of facing hard-
ened.
3. Replace driven plate.
4. Driven plate facing oil soaked.
4. Replace driven plate and check for
leaks.
5. Driven plate damper spring weakened
or broken.
5. Replace driven plate.
6. Pressure plate and/or flywheel warped.
6. Repair or replace.
Noisy
1. Release bearing binding.
1. Clean or replace if damaged, and lubri-
cate.
2. Release bearing worn or broken.
2. Replace.
3. Release bearing insufficiently lubricate.
3. Lubricate with grease or replace.
4. Driven plate damper springs weakened
or broken.
4. Replace driven plate.
5. Pilot bearing worn or broken.
5. Replace.
6. Driven plate rivet loosen.
6. Replace driven plate.
7. Ball stud insufficiently lubricate.
7. Lubricate with grease.
8. Clutch pedal lack of free play.
8. Readjust.
9. Clutch pedal shaft insufficiently lubri-
cate.
9. Lubricate with grease.
10. Pilot bearing loose or broken.
10. Replace.
Pedal is Hard to Push
1. hydraulic line blocked or crimped.
1. Clean out or replace.
2. Clutch pedal shaft insufficiently lubri-
cate.
2. Lubricate with grease.
00-4 SERVICE INFORMATION
MAIN DATA AND SPECIFICATIONS
Transmission
Power Take Off
Clutch
Type
MSB-5 5 Speed
Gear Mesh Type
1st to 5th:
Synchro-mesh
Reverse:
Constant-mesh
Control Type
Floor remote control
Gear Ratio
MSB-5S
MSB-5M
1st:
5.016
5.594
2nd:
2.672
2.814
3rd:
1.585
1.660
4th:
1.000
1.000
5th:
0.770
0.794
Reverse:
4.783
5.334
Lubricating Oil
Engine Oil SAE 5W-30
Oil Capacity
L (US
qt/Imp qt)
Approx. 2.7 (2.9/2.4)
AIlowable Maximum Torque
N
⋅m (kg⋅m / lb⋅ft)
147 (15/108.4) / at output shaft 1000 RPM
Gear Ratio (to Engine)
1.8214
Revolution Direction
Clockwise (viewed from rear)
Pressure Plate
NKR55
NHR55 / NKR55 / NHR69
Spring Type
Diaphragm
Diaphragm
Outside Diameter
mm (in)
240 (9.4)
250 (9.8)
Clamping Force
N (kg/lb)
4,119 (420/926)
6,276 (640/1,411)
Spring Finger Height
mm (in)
40.7 — 42.7 (1.60 — 1.68)
39.0 — 41.0 (1.54 — 1.61)
Driven Plate
Inside
× Outside Diameter
mm (in)
240
× 160 (9.4 × 6.3)
250
× 160 (9.8 × 6.3)
Free Thickness
mm (in)
7.5 — 8.1 (0.295 — 0.319)
8.1 — 8.7 (0.319 — 0.343)
Clamping Thickness
mm (in)
7.1 — 7.7 (0.280 — 0.303)
7.7 — 8.3 (0.303 — 0.327)
Clutch Pedal
Height
mm (in)
160 — 170 (6.3 — 6.7)
Stroke
mm (in)
159 — 169 (6.3 — 6.7)
Free Play
mm (in)
15 — 25 (0.6 — 1.0)
Master Cylinder
Bore Diameter
mm (in)
φ 19.050 — 19.102 (0.7500 — 0.7520)
SIave Cylinder
Bore Diameter
mm (in)
φ 26.990 — 27.042 (1.0626 — 1.0646)
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