Isuzu N-Series. Service manual — part 842
MANUAL TRANSMISSION 7B-29
Disassembly
Caution:
Be careful not to damage the transmission case and the
clutch housing because they are made of aluminum.
Further attention should be paid to the rib because its
damage weakens hardness of the case.
Do not hurt yourself when working on something heavy
such as cases and gears.
1. Remove the shift block assembly.
• Refer to CLUTCH.
2. Remove the shift fork and the support bolt.
• Refer to CLUTCH.
3. Remove the bolt securing the adjust hole cover
and remove the parking brake drum.
• Refer to PARKING BRAKE ASSEMBLY.
4. Raise the caulking portion (2 parts) of the coupling
driver lock nut securely, and then remove the lock
nut using the flange holder 5-8840-2043-0.
5. Remove the coupling driver and O-ring.
6. Remove the parking brake assembly.
• Refer to PARKING BRAKE ASSEMBLY.
7. Remove the filler plug and O-ring.
8. Remove the drain plug and O-ring.
• Drain the transmission oil. Check the amount of
oil and the existence of metal particles and for-
eign matters while draining oil.
9. Remove the speedometer driven gear (2).
10. Remove the reverse switch (3).
11. Remove the detent assembly (4)(5)(6).
12. Remove the control box (1) and the interlock plate
(7).
13. Remove the PTO cover (1).
14. Remove the reverse idle cover (2).
15. Remove the rear cover assembly.
16. If worn or damaged parts are found after checking
the rear cover oil seal, remove the oil seal from rear
cover using the flat-tip screwdriver.
17. Remove the speedometer gear and collar.
N7A0294E
N7A0311E
N7A0312E
7B-30 MANUAL TRANSMISSION
18. Remove the main shaft end lock nut using the
wrench 5-8840-2798-0. (4WD model)
19. Remove the retainer from the transmission case.
20. Pull out the reverse idle shaft, and then remove the
reverse idle gear and the needle bearing.
21. Remove the snap ring from the main shaft rear
bearing.
22. Remove the shim from the counter shaft rear bear-
ing.
23. Remove the transmission case from the clutch
housing.
24. Remove the bearing rear outer race from the trans-
mission case.
25. Remove the 4th-5th shift rod, 4th-5th main shift
block and 4th-5th sub shift block.
• When driving out the spring pin, put a round
pole on the opposite side of the shift rod not to
damage other parts, and then remove the
spring pin using the spring pin remover.
N7A0313E
N7A0314E
N7A1090E
N7A0316E
MANUAL TRANSMISSION 7B-31
26. Remove the 1st-reverse and 2nd-3rd shift rod, 1st-
reverse shift arm, 2nd-3rd shift arm, 1st-reverse
shift block, and 4th-5th shift arm.
• When driving out the spring pin, put a round
pole on the opposite side of the shift rod not to
damage other parts, and then remove the
spring pin using the spring pin remover.
27. Remove the bush from the 2nd-3rd shift arm using
the remover 5-8840-2755-0.
28. Remove the bush from the 4th-5th shift arm using
the remover 5-8840-2755-0.
• Use the remover with a round pole whose
length is enough to push the remover to the
end.
29. Remove the 5th relay lever from the clutch hous-
ing.
30. Remove the magnet from the clutch housing.
31. Remove the main shaft assembly, the top gear
shaft assembly and counter shaft assembly.
a. Tie the main shaft assembly, the counter shaft
assembly and the top gear shaft assembly at
the two positions not to let them come apart us-
ing a lashing belt or other belts with a fixing
function, and then fix them securely.
b. Install the bearing remover to the main shaft
and secure it with a lock nut, hang them with a
hoist and a wire, and then remove the top gear
shaft assembly, the main shaft assembly, the
counter shaft assembly from the clutch housing
as a unit while spreading the top gear shaft
bearing outer snap ring installed to the clutch
housing.
N7A0317E
N7A1093E
N7A1094E
N7A1095E
7B-32 MANUAL TRANSMISSION
32. Check the clutch housing bush, and then remove it
from the clutch housing using a pliers if it is worn or
damaged.
33. Check the front oil seal, and then remove it from
the clutch housing using a flat-tip screwdriver if it is
worn or damaged.
34. Check each part, and then correct and replace it if
some worn, damaged or faulty parts are found.
Check each part of the shift mechanism, and then
correct light damage, deflection or stepped wear.
Replace it when it is heavily damaged or its usage
limit is over.
• Deflection, wear and damage of the shift rod
and the shift arm
• Shift arm thickness
– Measure the thickness of the shift arm tip us-
ing the micrometer.
35. Check the wear of the speedometer driven gear
and the driven gear bush.
• Replace them if they are heavily worn.
N7A1096E
N7A1097E
N7A1098E
Shift arm thickness, mm (in)
Standard
Limit
1st-reverse
3rd-2nd
5th-4th
9.60 — 9.85
(0.377 —
0.387)
9.0 (0.354)
N7A1100E
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