Isuzu Trooper (2000 year). Service manual — part 418

MANUAL TRANSMISSION

7B–1

TROOPER

TRANSMISSION

MANUAL TRANSMISSION

CONTENTS

Service Precaution

7B–1

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General Description

7B–2

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Diagnosis

7B–3

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Manual Transmission Assembly

7B–4

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Removal

7B–4

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Installation

7B–8

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Disassembled View

7B–13

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Disassembly

7B–16

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Inspection

7B–34

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Reassembly

7B–36

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Main Data and Specifications

7B–62

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Special Tools

7B–64

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Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

7B–2

MANUAL TRANSMISSION

General Description

A07RW023

MANUAL TRANSMISSION

7B–3

Diagnosis

Condition

Possible cause

Correction

Abnormal noise

Flywheel pilot bearing worn

Replace

Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)

Replace

Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)

Replace

Splines worn (Mainshaft,
synchronizer clutch hub)

Replace

Gear or bearing thrust face seized

Replace

Lack of backlash between meshing
gears

Replace

Hard Shifting

Improper clutch pedal free play

Readjust

Change lever sliding portions worn

Repair or replace
Regrease

Shift block, shift rod and/or control
box sliding faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Synchronizer parts worn

Replace

Walking or Jumping out of gear

Detent ball worn

Replace

Detent spring weakened or broken

Replace

Shift rod and/or control box sliding
faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Bearings worn or broken

Replace

Splines worn (Mainshaft,
synchronizer hub)

Replace

Synchronizer spring weakened or
broken

Replace

Oil leakage

Loose drain plug(s) and/or filler
plug(s)

Tighten
Replenish oil

Defective or improperly installed
gasket(s)

Replace

Oil seal worn or scratched

Replace

7B–4

MANUAL TRANSMISSION

Manual Transmission Assembly

Removal

NOTE: Before remove the transmission and transfer
assembly from the vehicle, change the transfer mode to
2WD using push button on dash panel.

1. Remove engine hood.
2. Disconnect battery ground cable.
3. Remove the gear control lever knob.
4. Remove the front console assembly.
5. Remove the grommet assembly.
6. Remove the transmission control lever and transfer

control lever.

235RX001

7. Remove transfer protector.
8. Remove the rear propeller shaft.

NOTE: Apply alignment marks on the flange at the both
front and rear side.

401RS002

9. Remove the front propeller shaft.

NOTE: Apply alignment marks on the flange at both the
front and rear sides.

401RS003

10. Disconnect the reverse lamp switch, 4WD indicator

switch, and 1-2 indicator switch harness connectors.

230RW005