Isuzu N-Series. Service manual — part 805
SERVICE INFORMATION 00-5
SERVICE STANDARD
Transmission
Items
Service Standard
Service Limit
Gear Shift Position between Center
of Shift Lever Play and Instrument
Center Cluster
mm (in)
Standard Cab: 247
±15 (9.7±0.6)
Wide Cab: 283
±15 (11.1±0.6)
Ball Bearing Run-out
mm (in)
0.2 (0.01)
Gear Inside Diameter
mm (in)
1st Gear: 61 (2.402)
61.1 (2.406)
2nd Gear: 54 (2.126)
54.1 (2.130)
3rd Gear: 42 (1.654)
42.1 (1.657)
Reverse Gear: 54 (2.126)
54.1 (2.130)
Clearance between 5th Gear and
Main Shaft
mm (in)
0.05 — 0.09 (0.002 — 0.004)
0.2 (0.01)
Clearance between Reverse Idle
Gear and Idle Gear Shaft
mm (in)
0.04 — 0.08 (0.002 — 0.003)
0.2 (0.01)
Spline Play between 5th Counter
Gear and Counter Shaft at 5th
Counter Gear Outer Circumference
mm (in)
0.18 — 0.43 (0.007 — 0.017)
0.45 (0.018)
Thrust Washer Thickness
mm (in)
2nd: 3.0 (0.12)
2.8 (0.11)
5th: 3.8 (0.15)
3.6 (0.14)
Main Shaft Run-out
mm (in)
Less than 0.025 (0.0010)
0.1 (0.004)
Clearance between Block Ring and
Dog Gear
mm (in)
3rd/4th: 1.0 (0.04)
0.5 (0.02)
1st/2nd: 1.5 (0.06)
0.5 (0.02)
5th: 1.5 (0.06)
0.5 (0.02)
Spline Play between Clutch Hub and
Main Shaft at Clutch Hub Outer Cir-
cumference
mm (in)
Less than 0.05 (0.002)
0.3 (0.01)
Clearance between Block Ring and
Insert
mm (in)
3.59 — 3.91 (0.141 — 0.154)
4.1 (0.16)
Clearance between Clutch Hub and
Insert
mm (in)
0.09 — 0.31 (0.004 — 0.012)
0.4 (0.02)
Shift Arm Thickness
mm (in)
10.0 (0.39)
9.0 (0.35)
Detent Spring Free Length
mm (in)
31.6 (1.24)
30.1 (1.19)
00-6 SERVICE INFORMATION
Clutch
Items
Service Standard
Service Limit
Pressure Plate Distortion
mm (in)
0.3 (0.01)
Pressure Plate Clamping Force
N (kg/lb)
NKR55 Clutch Size
φ 240
4,116 (420/926)
3,785 (386/851)
NHR55 / NKR55 / NHR69 Clutch Size
φ 250
6,276 (640/1,411)
5,776 (589/1,299)
Diaphragm Spring Finger Height
mm (in)
NKR55 Clutch Size
φ 240
40.7 — 42.7 (1.60 — 1.68)
NHR55 / NKR55 / NHR69 Clutch Size
φ 250
39.0 — 41.0 (1.54 — 1.61)
Driven Plate Warpage
mm (in)
Less than 0.7 (0.03)
1.0 (0.04)
Spline Play between Top Gear Shaft
and Driven Plate at Driven Plate
Outer Circumference
mm (in)
Less than 0.5 (0.02)
1.0 (0.04)
Driven Plate Rivet Head Depression
mm (in)
NKR55 Clutch Size
φ 240
1.1 — 1.7 (0.04 — 0.01)
0.2 (0.01)
NHR55 / NKR55 / NHR69 Clutch Size
φ 250
1.65 — 2.25 (0.06 — 0.09)
0.2 (0.01)
Clutch Pedal Height
mm (in)
160 — 170 (6.3 — 6.7)
Clutch Pedal Stroke
mm (in)
159 — 169 (6.3 — 6.7)
Clutch Pedal Free Play
mm (in)
15 — 25 (0.6 — 1.0)
Clearance between Pedal Stopper
and Clutch Switch Thread End or
Stopper Bolt
mm (in)
0.5 — 1.0 (0.02 — 0.04)
Master Cylinder Bore Diameter
mm (in)
19.050 — 19.102 (0.7500 — 0.7520)
Clearance between Master Cylinder
Bore and Piston
mm (in)
0.03 — 0.11 (0.001 — 0.004)
0.12 (0.005)
Slave Cylinder Bore Diameter
mm (in)
26.990 — 27.042 (1.0626 — 1.0646)
Clearance between Slave Cylinder
Bore and Piston
mm (in)
0.02 — 0.10 (0.0008 — 0.0039)
0.11 (0.0043)
SERVICE INFORMATION 00-7
SERVICING
Transmission Oil Level Check
1. Remove Filler Plug.
2. Check Oil Level.
• Add lubricant to within 0 to10 mm (0 to 0.4 in)
of bottom edge of the filler hole if necessary.
Caution:
Use ENGINE OIL SAE 5W-30 for transmission case.
3. Install Filler Plug.
Tighten:
Filler plug to 49 N
⋅m (5.0 kg⋅m / 36 lb⋅ft)
Transmission Oil Change
1. Drain Oil.
• Remove the drain plug from the transmission
case and drain the oil.
2. Install Drain Plug.
Tighten:
Drain plug to 49 N
⋅m (5.0 kg⋅m / 36 lb⋅ft)
3. Remove Filler Plug.
4. Fill Oil.
• Fill the transmission case from the filler plug
hole with new oil of specified grade.
Caution:
Use ENGINE OIL SAE 5W-30 for transmission case.
5. Install Filler Plug.
Tighten:
Filler plug to 49 N
⋅m (5.0 kg⋅m / 36 lb⋅ft)
Gear Control Cable Adjustment
1. Measure
• Set the change lever in the neutral position,
then confirm if the dimension (L) between the
center of the change lever play and the instru-
ment center cluster is within the reference val-
ue.
Legend
1. Filler plug
2. Drain plug
Oil Capacity
Liters (US
⋅qt/Imp⋅qt)
2.7 (2.9/2.4)
N7A0001E
Change Lever Position
mm (in)
Standard Cab: 247
±15 (9.7±0.6)
Wide Cab: 238
±15 (11.1±0.6)
N7A0002E
00-8 SERVICE INFORMATION
2. Adjust
• If the dimension is out of the reference, adjust
as required.
1) Remove the change lever knob.
2) Remove the cover assembly.
3) Disconnect the shift cable from the change le-
ver.
4) Set the transmission in the neutral position.
5) Loosen the lock nut of the shift cable ball joint
and the select cable turnbuckle, then turn the
ball joint and turnbuckle as necessary for hole
and pin.
6) Tighten the lock nuts and install the shift cable
to the change lever.
Tighten:
Lock nut to 6 N
⋅m (0.6 kg⋅m / 4.4 lb⋅ft)
7) Install the cover assembly and the change le-
ver knob.
Clutch Pedal Travel and Free Play Adjust-
ment
Clutch Pedal Height and Stroke
1. Remove Meter Cluster.
• Pull out the meter cluster and disconnect the
harness connectors.
Legend
1. Knob
2. Cover assembly
3. Change lever
4. Shift cable
5. Snap pin
6. Select cable
N7A0003E
Legend
1. Shift cable (transmission side)
2. Select cable (transmission side)
3. Ball joint
4. Turnbuckle
5. Lock nut (change lever side)
N7A0004E
N7A0005E
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