Isuzu N-Series. Service manual — part 968
7B-108 Automatic Transmission (Smoother)
17. Use a caliper to measure the gap between the
insert key and block ring groove.
• If the measured value exceeds the specified
value, replace the insert key and block ring.
18. Use a thickness gauge to measure the gap
between the insert key and clutch hub.
• If the measured value exceeds the specified
value, replace the insert key and clutch hub.
19. Use a thickness gauge to measure the gap
between the index block and clutch hub.
• If the measured value exceeds the limit,
replace the index block and clutch hub.
Assembly
• Thoroughly clean each part.
Gap Between the Insert Key and Block Ring Groove
(mm)
Specified Value
4th/5th/6th
3.46 — 3.76
Gap Between the Insert Key and Clutch Hub (mm)
Specified Value
4th/5th/6th
0.01 — 0.21
N7A1206E
N7A1207E
Gap Between the Index Block and Clutch Hub (mm)
Specified Value
2nd/3rd
4.30 — 4.70
Legend
1. Index Block
2. Clutch Hub
N7A1208E
N7A1209E
Automatic Transmission (Smoother) 7B-109
• Set the main shaft into a vice, with the long spline
length downwards. At this time, take care to avoid
damage to the grinding surface.
1. Perform the following steps to assemble the 2nd —
3rd clutch hub assembly and sleeve.
a. Install the index block and spring onto the
clutch hub.
b. There are three ball grooves on the inner
surface of the sleeve. Align the phase so the
balls are in the center of the ball grooves.
c. Insert the sleeve (1) on the clutch hub (5) until
the index block is slightly covered.
d. While pressing in the balls (2), index block (2),
and spring (4), securely insert the sleeve until
balls enter the sleeve ball grooves.
2. Apply engine oil to the needle bearing, 2nd gear
thrust surface and synchro cone taper. With the
dog gear upwards, install the 2nd gear (6) and
needle bearing (5) on the main shaft.
3. Install the 2nd inside ring (4), 2nd outside ring (3)
and 2nd block ring (2) so the outside ring claw
enters the hole in the 2nd gear dog gear. At this
time, apply engine oil to the bore surface of the
inside ring and outside ring, and the bore surface
of the block ring.
4. Install the 2nd — 3rd clutch hub assembly and
sleeve (1) so the six inside ring claws are aligned
with the six holes of the hub, and use an installer
(5-8840-2345-0) to press-fit.
5. Install the 3rd block ring (7), 3rd outside ring (6),
and 3rd inside ring (5) so their six inside ring claws
align with the six holes of the hub. At this time,
apply engine oil to the bore surface of the inside
ring and outside ring, and the bore surface of the
block ring.
N7A1210E
N7A1211E
N7A1212E
7B-110 Automatic Transmission (Smoother)
6. Apply engine oil to the needle bearing, 3rd gear
thrust surface, and synchro cone taper. With the
dog gear facing downwards, use an installer (5-
8840-2345-0) to press-fit the 3rd gear (4), needle
bearing (3), and collar (2) so the outer ring claw
aligns with the 3rd gear dog gear hole.
7. Use snap ring pliers to install the snap ring (1).
Caution:
If the snap ring is deformed or damaged, replace it with
a new one and check to make sure it is installed
securely.
8. Perform the following steps to assemble the 4th —
5th clutch hub assembly and sleeve.
a. Securely assemble the insert key (2) into the
block ring insert key groove.
b. Install the insert spring (3) on the insert key as
shown in the illustration.
Caution:
• When assembling the insert spring, make sure that
the surplus length on either end of the spring is
about the same that it does not interfere with the
interior diameter of the hub.
• The insert spring opening on the back should not
be in the same position as the front opening.
N7A1213E
N7A1172E
N7A1173E
Automatic Transmission (Smoother) 7B-111
c. Confirm that the clutch hub (4) and sleeve (5)
slide smoothly.
• The arrow (1) indicates the front of the
transmission.
9. Apply engine oil to the needle bearing, 4th gear
thrust surface and synchro cone taper. With the
dog gear upwards, install the 4th gear (5) and
needle bearing (4).
10. Apply engine oil to the 4th block ring (3), and
install.
11. With the oil groove surface of the 4th — 5th clutch
assembly and sleeve (2) facing downwards, align
with the pass of the 4th — 5th block ring groove
and use an installer (5-8840-23450-0) to press-fit.
12. Use snap ring pliers to install the snap ring (1).
Caution:
If the snap ring is deformed or damaged, replace it with
a new one and check to make sure it is installed
securely.
13. Assemble the 1st — Reverse clutch hub assembly
and sleeve.
14. Apply engine oil to the needle bearing, 1st gear
thrust surface and synchro cone taper. With the
dog gear upwards, install the 1st gear (3) and
needle bearing (2).
N7A1216E
N7A1217E
Legend
1. Clutch Hub
2. Sleeve
N7A1218E
N7A1196E
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