Isuzu N-Series. Manual — part 862
MANUAL TRANSMISSION 7B-109
8. Install the bearing of the rear output gear shaft.
• Use a press machine to press in the ball bear-
ing.
9. Install the front output gear shaft to the front trans-
fer case.
10. Install the input gear shaft.
11. Install the rear output gear shaft.
12. Install the idle gear shaft.
• Install in the order of 9, 10, 11 and 12.
13. Install the thrust washer and speedometer drive
gear.
14. Install the shift arm and shift rod.
• Use a spring pin to install the shift arm of the
low / high change side.
• Use a bolt to fix the shift arm of the 2WD / 4WD
change side. Apply LOCTITE 242 to the
threaded part of the bolt.
Tighten:
Shift arm and shift rod to 23 N
⋅m (2.3 kg⋅m / 17 lb⋅ft)
15. Install the rear transfer case.
• Apply liquid packing (ThreeBond 1215) to the
mating surface of the front transfer case. Liquid
packing must be applied to the inside of the bolt
hole continuously with a diameter of 2 mm
(0.079 in).
Legend
1. Input gear shaft
2. Idle gear shaft
3. Front output gear shaft
4. Rear output gear shaft
N7A0472E
N7A0473E
N7A0453E
N7A0452E
7B-110 MANUAL TRANSMISSION
• Do not drop the detent shaft.
• Align with the 2 knock pins.
• Set the 18 bolts on the fixing holes, and fix them
diagonally and equally.
Tighten:
Transfer case to 33 N
⋅m (3.4 kg⋅m / 24 lb⋅ft)
16. Install the shift lever.
• Check that the internal lever is securely put in
the groove of the shift arm.
• Apply liquid packing (ThreeBond 1215) to the
mating surfaces of the shift cover and transfer
case, and fix it with a bolt.
Tighten:
Shift lever to 17 N
⋅m (1.7 kg⋅m / 13 lb⋅ft)
17. Install the detent balls and springs in two parts.
• Install the detent balls and springs for 4H & 4L
and 2WD & 4WD to the rear transfer case.
• Apply liquid gasket (ThreeBond 1105) to the
thread of the plug, and fix it to the specified
torque.
Tighten:
Plug to 25 N
⋅m (2.5 kg⋅m / 18 lb⋅ft)
Caution:
Do not drop the parts.
18. Install the low / high shift lever cable installation
bracket.
N7A0476E
N7A0477E
Legend
1. Spring pin
2. Select external lever
3. Select internal lever
N7A0448E
N7A0449E
MANUAL TRANSMISSION 7B-111
• Apply liquid gasket (ThreeBond 1215) only to
the thread of the bolt, which is to be fixed
through the bore hole of the case side.
Tighten:
Bolt to 17 N
⋅m (1.7 kg⋅m / 13 lb⋅ft)
19. Install the 2WD / 4WD change warning lamp
switch.
• Apply liquid gasket (ThreeBond 1105) to the
switch thread.
Tighten:
2WD / 4WD change warning lamp switch to 33 N
⋅m (3.4
kg
⋅m / 25 lb⋅ft)
20. Install the rear & front coupling driver.
• Use the flange holder 5-8840-0133-0 to fix the
front coupling driver, and tighten it with a lock
nut.
• After installing the parking brake assembly, use
the coupling driver and lock nut to install the
rear output shaft.
Tighten the lock nut by fixing the coupling driver
using the flange holder 5-88470-2043-0.
Tighten:
• Parking brake to 83 N
⋅m (8.5 kg⋅m / 61 lb⋅ft)
• Front output shaft to 290 N
⋅m (29 kg⋅m / 214 lb⋅ft)
• Rear output shaft to 226 N
⋅m (23 kg⋅m / 167 lb⋅ft)
• After tightening to the specified torque, align
the lip part of the nut to the V-groove of the
shaft edge. Caulk the nut lip with a chisel to
make a length (B) of 5 mm (0.2 in) or more, and
a clearance between the bottom of the shaft
and the nut lip (A) of 2.5 mm (0.06 in) or less.
Caution:
When caulking, be careful not to crack the nut.
21. Install the parking brake drum.
• Tighten the adjustment hole cover fixing bolt.
N7A0480E
MIN
5.0mm
MIN
5.0mm
MAX
2.5mm
MAX
2.5mm
A
B
N7A0297E
7B-112 MANUAL TRANSMISSION
Special Tools
Illustration
Tool Number /
Description / Remarks
5-8840-2772-0 / Bearing
Installer
5-8840-2773-0 / Bearing
Installer
5-8840-2774-0 / Bearing
Installer
5-8840-2775-0 / Oil Seal
Installer
5-8840-2776-0 / Oil Seal
Installer
5-8840-0194-0 / Shim
Selector
5884027720
5884027730
5884027740
5884027750
5884027760
5884001940
5-8840-2235-0 / Bearing
Installer
5-8840-2794-0 / Shim
Selector Adapter Kit
5-8840-0007-0 / Grip
5-8840-2043-0 / Flange
Holder
5-8840-2587-0 / Bearing
Remover
5-8840-0027-0 /
Remover
Illustration
Tool Number /
Description / Remarks
5884022350
5884027940
5884000070
5884020430
5884025870
5884000270
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