Isuzu Trooper (1998-2002 year). Service manual — part 810
7B–50 MANUAL TRANSMISSION
15. Inspect each gear radial clearance.
1. Mount the mainshaft through the aluminum plate
in a vise.
2. Using a dial indicator, measure the radial
clearance of each gear.
Gear
Standard Clearanse
1st
0.020 – 0.073 mm (0.0008 – 0.0029 in)
2nd
0.015 – 0.068 mm (0.0006 – 0.0027 in)
3rd
0.015 – 0.068 mm (0.0006 – 0.0027 in)
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16. Install the counter gear shaft.
1. Check the new counter front bearing inner race
and the side race, as shown.
2. Using installer 5–8840–2556–0 (J–42800) and a
press, install the counter gear shaft front bearing.
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3. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A
2.00 – 2.05 mm (0.079 – 0.081 in)
B
2.05 – 2.10 mm (0.081 – 0.083 in)
C
2.10 – 2.15 mm (0.083 – 0.085 in)
D
2.15 – 2.20 mm (0.085 – 0.087 in)
E
2.20 – 2.25 mm (0.087 – 0.089 in)
F
2.25 – 2.30 mm (0.089 – 0.091 in)
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4. Using a snap ring expander, install the new snap
ring.
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MANUAL TRANSMISSION
7B–51
17. Install the front cover.
1. Using installer 5–8840–2557–0 (J–42801), grip
5–8840–0007–0 (J–8092) and a hammer, drive in
a new oil seal.
Drive in depth (from cover end): 11.7
±
0.5 mm
(0.46
±
0.02 in)
2. Apply grease to the seal lip.
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18. Install the transfer adapter.
1. Using installer 5–8840–2558–0 (J –42802), and a
hammer drive in a new oil seal.
Drive in depth (from transfer adapter):
10.95
±
0.5 mm (0.431
±
0.02 in)
2. Apply grease to the oil seal lip.
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3. Install the oil receiver pipe.
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4. Install the reverse restrict to the transfer adapter.
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7B–52 MANUAL TRANSMISSION
5. Using a pin punch and hammer, drive in the
slotted spring pin.
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6. Clean up the plug and plug hole.
7. Apply sealant to the plug threads. (THREE BOND
1344 or equivalent)
8. Using a torx socket wrench(T40), install and
torque the plug.
Torque: 19 N·m (1.9 kg·m/14 lb ft)
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9. Using hexagon wrench, install and torque the
plug.
Torque: 37 N·m (3.8 kg·m/27 lb ft)
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19. Install the reverse shift arm No.1 and reverse shift
arm No.2.
1. Mount the intermediate plate through the
aluminum plate in a vise.
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MANUAL TRANSMISSION
7B–53
2. Using 2 bolts, install reverse shift arm bracket.
Torque: 18 N·m (1.8 kg·m/13 lb ft)
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3. Install reverse shift arm No.2 to the reverse shift
arm No.1. Using screwdriver and a hammer,
install the new E-ring.
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4. Install reverse shift arm No.2 to the reverse shift
arm bracket.
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20. Install the reverse shift rod.
1. Install the reverse shift arm No.1 compression
spring and ball to the reverse shift arm No.1.
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