Isuzu N-Series. Manual — part 820
7B-50 MANUAL TRANSMISSION (MSB)
6. 1st Gear
• Install the 1st gear with its taper cone side up-
ward (front of transmission).
7. Block Ring
• Align the insert groove of the block ring with the
insert.
8. 1st/2nd Synchronizer Assembly
• Assemble the sleeve to the clutch hub. The
clutch hub has no specific directionality.
• Put the inserts into the clutch hub groove, and
install the insert spring.
• Assemble the insert springs so that the distanc-
es (A and B) between inserts and the opening
of the spring can be nearly equal, and also this
opening may not be the same direction on both
side.
• Larger width side of the sleeve outer circumfer-
ence should be positioned toward the 1st gear
side (rear of transmission).
• Align the insert with the insert groove of the
block ring.
N7A0162E
N7A0163E
N7A0164E
N7A0165E
MANUAL TRANSMISSION (MSB) 7B-51
• Tap the clutch hub boss section with a plastic
hammer to press it in until it contacts closely
with the main shaft stepped section.
• When it is difficult to engage the clutch hub
boss with the main shaft spline, heat the clutch
hub boss section to a temperature between 80
and 120
°C (176 and 248°F) with the piston
heater before assembling.
• Check to see if the 1st gear rotates smoothly.
9. Snap Ring
• Install the built-in snap ring and measure the
clearance between the snap ring and the clutch
hub.
• When the clearance is out of the reference val-
ue, select a snap ring with the maximum thick-
ness that can be inserted from among the
following three types, and built it in.
10. Block Ring
• Align the insert groove of the block ring with the
insert.
11. Needle Bearing
Legend
1. Smaller
2. Larger
3. 1st gear
N7A0166E
N7A0167E
Clutch Hub and Snap Ring Clearance
mm (in)
0 — 0.09 (0 — 0.004)
Snap Ring
mm (in)
Color
Thickness (Reference)
Pink
1.75 — 1.80 (0.069 — 0.071)
White
1.80 — 1.85 (0.071 — 0.073)
Yellow
1.85 — 1.90 (0.073 — 0.075)
N7A0028E
N7A0027E
7B-52 MANUAL TRANSMISSION (MSB)
12. 2nd Gear
• Install the 2nd gear with the taper cone side
turned to the 1st gear side (to the bottom).
13. Thrust Washer
• With the thrust washer set to main shaft groove,
assemble it.
14. Snap Ring
• After installation, measure distance (T) and se-
lect the optimum snap ring from the table.
15. Needle Bearing
16. 3rd Gear
N7A0026E
N7A0025E
Snap Ring
mm (in)
Distance
(T)
Color
Thickness
(Reference)
2.20 — 2.27
(0.087 — 0.089)
Yellow
1.85 — 1.90
(0.073 — 0.075)
2.27 — 2.32
(0.089 — 0.091)
Blue
1.90 — 1.95
(0.075 — 0.077)
2.32 — 2.37
(0.091 — 0.093)
Brown
1.95 — 2.00
(0.077 — 0.079)
2.37 — 2.43
(0.093 — 0.096)
Green
2.00 — 2.05
(0.079 — 0.081)
Legend
1. 1st
2. 2nd
N7A0168E
N7A0024E
MANUAL TRANSMISSION (MSB) 7B-53
• Install with the taper cone side turned upward
(front of transmission).
17. Block Ring
18. 3rd/4th Synchronizer Assembly
• Mate the clutch hub and the sleeve so that the
larger diameter side of the clutch hub boss and
the identification groove of the sleeve outer cir-
cumference point to the same direction.
• Put the inserts into the clutch hub groove, and
install the insert spring.
• Assemble the insert springs so that the distanc-
es (A and B) between inserts and the opening
of the spring can be nearly equal, and also this
opening may not be the same direction on both
side.
• Grooved face of the sleeve and the larger boss
of clutch hub should be positioned toward the
3rd gear (rear of transmission).
• Align the insert groove of the block ring with the
insert.
• Tap the clutch hub boss section with a plastic
hammer to press it in until it contacts closely
with the main shaft stepped section.
• When it is difficult to engage the clutch hub
boss with the main shaft spline, heat the clutch
hub boss section to a temperature between 80
and 120
°C (176 and 248°F) with the piston
heater before assembling.
• Check to see if the 3rd gear rotates smoothly.
Legend
1. Larger
2. Groove
N7A0169E
N7A0170E
Legend
1. Larger
2. Groove
3. 3rd gear
N7A0165E
N7A0171E
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