Isuzu N-Series. Service manual — part 854
MANUAL TRANSMISSION 7B-77
8. Remove from the main shaft the following parts us-
ing a bearing remover with a press; the collar, 3rd
gear, needle bearing, 3rd inside ring, 3rd outside
ring, 3rd block ring, 2nd-3rd clutch hub assembly &
sleeve, 2nd block ring, 2nd outside ring, 2nd inside
ring, 2nd gear, needle bearing.
9. Disassemble the 2nd-3rd clutch hub assembly &
sleeve.
Inspect each part. If any wear, damage or other abnor-
mality is found, repair or replace the part.
10. Inspect each bearing with respect to the following
items. If any abnormality is found, replace the item.
• Smoothness of rotation
• Noise
• Abnormal external appearance, including dam-
age, rust, etc.
11. Inspect the inside diameter of the gear.
• Measure the inside diameter of each gear us-
ing an inside dial gauge.
• If the measured value exceeds the limit, re-
place the gear.
12. Inspect the deflection of the main shaft.
• Measure the deflection of the main shaft using
a dial gauge.
• If the measured value exceeds the limit, re-
place the main shaft.
Standard: 0.015 mm (0.00059 in)
Limit: 0.1 mm (0.00393 in)
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
N7A1199E
N7A1200E
Gear Inside Diameter, mm (in)
Standard
Limit
6th gear
50.009 — 50.025
(1.968 — 1.969)
50.065
(1.971)
4th gear
44.009 — 44.025
(1.732 — 1.733)
44.065
(1.734)
3rd gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
2nd gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
1st gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
Reverse Gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
N7A1201E
7B-78 MANUAL TRANSMISSION
13. Inspect the synchromesh system.
• Inspect the components. Repair the slight
stepped wear and damage using an oil stone or
a pencil grinder.
14. Measure the clearance between the block ring and
the dog gear using a thickness gauge.
• If the measured value exceeds the limit, re-
place the block gear.
15. Inspect the sliding part, spline part, inserting part
and insert groove of the clutch hub and sliding
sleeve for wear and damage.
16. Measure the free play in the direction of spline ro-
tation on the clutch hub external circumference.
• If the measured value exceeds the limit, re-
place the part.
Clearance between Block Ring and Dog Gear, mm
(in)
Standard
Limit
4th / 5th / 6th /
Reverse
1.30 — 2.60
(0.051 — 0.102)
0.5 (0.019)
2nd / 3rd
1.00 — 2.50
(0.039 — 0.098)
0.5 (0.019)
1st
1.00 — 2.50
(0.039 — 0.098)
0.5 (0.019)
N7A1202E
N7A1203E
Legend
1. Block ring
2. Outside ring
3. Inside ring
Spline Free Play, mm (in)
Standard
Limit
0 — 0.05 (0 — 0.0019)
0.3 (0.0118)
N7A1204E
N7A1205E
MANUAL TRANSMISSION 7B-79
17. Measure the clearance between the insert and
block ring groove using a caliper.
• If the measured value exceeds the limit, re-
place the insert and block ring.
18. Measure the clearance between the insert and
clutch hub using a thickness gauge.
• If the measured value exceeds the limit, re-
place the insert and clutch hub.
19. Measure the clearance between the block ring and
the clutch hub using a thickness gauge.
• If the measured value exceeds the limit, re-
place the block and clutch hub.
Assembly
• Clean up each part.
• Set the main shaft in a vise, with the long spline
part at the bottom.
Clearance between Insert and Block Ring Groove,
mm (in)
Standard
4th / 5th / 6th
3.46 — 3.76 (0.136 — 0.148)
Clearance between Insert and Clutch Hub, mm (in)
Standard
4th / 5th / 6th
0.01 — 0.21 (0.00039 — 0.00826)
N7A1206E
N7A1207E
Clearance between Block Ring and Clutch Hub, mm
(in)
Standard
2nd / 3rd
4.30 — 4.70 (0.16929 — 0.18503)
1st / Reverse
4.30 — 4.70 (0.16929 — 0.18503)
Legend
1. Block ring
2. Clutch hub
N7A1208E
N7A1209E
7B-80 MANUAL TRANSMISSION
When setting the main shaft, make sure not to
damage the grind surface.
1. Assemble the 2nd-3rd clutch hub assembly &
sleeve following the procedure below.
a. Install the block and sleeve to the clutch hub.
b. Inside the sleeve, there are three ball grooves.
Align the phase to let the ball enter the center
of the ball grooves.
c. Insert sleeve (1) until the clutch hub (5) slightly
overlaps the block.
d. Securely insert the sleeve until the ball enters
the ball groove of the sleeve by pushing the ball
(2), block (3) and spring (4).
2. Apply engine oil 5W-30 to the needle bearing, 2nd
gear thrust surface and synchro cone taper sur-
face. And install the 2nd gear (6) and needle bear-
ing (5) to the main shaft with the dog gear turned
upward.
3. Install the 2nd inside ring (4), 2nd outside ring (3)
and 2nd block ring (2) inserting the nail of the out-
side ring into the gear hole of the 2nd gear. At this
time, make sure to apply engine oil 5W-30 suffi-
ciently to the both sides of the inside ring and out-
side ring, and inside diameter surface of the block
ring.
4. Insert the 2nd-3rd clutch hub assembly & sleeve
with a press using the installer 5-8840-2345-0, set-
ting the six nails of the inside ring to enter the six
holes of the hub.
5. During installation, set the six nails of the inside
ring of the 3rd block ring (7), 3rd outside ring (6)
and 3rd inside ring (5) to enter the six hub holes, re-
spectively. At this time, apply engine oil 5W-30 suf-
ficiently to the inside surface of the outside ring and
the inside diameter surface of the block ring.
6. Apply engine oil 5W-30 to the needle bearing, 3rd
gear thrust surface and synchro cone taper. Turn
the dog gear downward, and insert the 3rd gear
(4), needle bearing (3) and collar (2) using the in-
staller 5-8840-2345-0 with a press, setting the nail
of the outer ring to enter the dog gear hole of the
3rd gear.
7. Install the snap ring (1) using snap ring pliers.
Caution:
Replace deformed or damaged snap rings with new
ones. Check that the parts are securely installed.
N7A1210E
N7A1211E
N7A1212E
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