Isuzu N-Series. Manual — part 965
7B-96 Automatic Transmission (Smoother)
• If the measured value exceeds the limit,
replace the main shaft.
Specified value: 0.015 mm Limit: 0.1 mm
12. Inspect the synchromesh mechanism.
• Inspect the component parts. Use an oil stone
or pencil grinder to repair any minute stepped
wear or damage.
13. Gap between the block ring and dog gear
• Use a thickness gauge to measure the gap.
• If the measured value exceeds the limit,
replace the block ring.
14. Inspect the sliding part of the clutch hub and sliding
sleeve, the insert key of the spline, and the insert
key groove for wear and damage.
15. Measure the play in the spline rotation direction (on
the clutch hub outer circumference).
• If the measured value exceeds the limit,
replace.
Gap Between the Block Ring and Dog Gear (mm)
Specified
Value
Limit
4th/5th/Reverse
1.30 — 2.60
0.5
2nd/3rd
1.00 — 2.50
0.5
1st
1.00 — 2.50
0.5
N7A1202E
N7A1203E
Legend
1. Block Ring
2. Outside Ring
3. Inside Ring
Spline Play (mm)
Specified Value
Limit
0 — 0.05
0.3
N7A1204E
N7A1205E
Automatic Transmission (Smoother) 7B-97
16. Use a caliper to measure the gap between the
insert key and block ring groove.
• If the measured value exceeds the limit,
replace the insert key and block ring.
17. Use a thickness gauge to measure the gap
between the insert key and clutch hub.
• If the measured value exceeds the limit,
replace the insert key and clutch hub.
18. Use a thickness gauge to measure gap A between
the index block and clutch hub.
• If the measured value exceeds the specified
value, 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
3.46 — 3.76
Gap Between the Insert Key and Block Ring Groove
(mm)
Specified Value
4th/5th
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
7B-98 Automatic Transmission (Smoother)
• 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 both surfaces 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
Automatic Transmission (Smoother) 7B-99
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.
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
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