Isuzu N-Series. Manual — part 851
MANUAL TRANSMISSION 7B-65
Disassembly
1. Remove simultaneously the following parts with a
press using a bearing remover; the bearing, spac-
er, collar, reverse gear, needle bearing, reverse
block ring, 1st-reverse clutch hub assembly &
sleeve, 1st block ring, 1st outside ring, 1st inside
ring, 1st gear, and needle bearing.
2. Disassemble the 1st-reverse clutch hub & sleeve.
3. Remove the 4th-5the clutch hub assembly fixing
snap ring using snap ring pliers.
4. Remove simultaneously the following parts with a
press using a bearing remover; the 4th-5th clutch
hub assembly & sleeve, 5th block ring, 5th gear,
needle bearing.
Legend
1. Snap ring
17. 3rd outside ring
2. 4th-5th clutch hub assembly and sleeve
18. 3rd inside ring
3. 5th block ring
19. Main shaft
4. 5th gear
20. Needle bearing
5. Needle bearing
21. 1st gear
6. Snap ring
22. 1st inside ring
7. Collar
23. 1st outside ring
8. Needle bearing
24. 1st block ring
9. 3rd gear
25. Bearing
10. Needle bearing
26. Spacer
11. 2nd gear
27. Collar
12. 2nd inside ring
28. Needle bearing
13. 2nd outside ring
29. Reverse gear
14. 2nd block ring
20. Reverse block ring
15. 2nd-3rd clutch hub assembly and sleeve
31. 1st-reverse clutch hub assembly & sleeve
16. 3rd block ring
N7A1195E
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
1
5
4
3
2
N7A0372E
7B-66 MANUAL TRANSMISSION
5. Disassemble the 4th-5th clutch hub assembly &
sleeve.
6. Remove the 3rd gear collar fixing snap ring using
snap ring pliers.
7. Remove simultaneously from the main shaft the
following parts with a press using a bearing remov-
er; the collar, 3rd gear, needle bearing, 3rd inside
ring, 3rd outside ring, 3rd block ring, 2nd-3rd clutch
hub assembly & sleeve, 2nd block ring, 2nd out-
side ring, 2nd inside ring, 2nd gear, and needle
bearing.
8. Disassemble the 2nd-3rd clutch hub assembly &
sleeve.
Inspect each part, and if any wear, damage and
other abnormality is found, repair or replace the
item.
9. Inspect each bearing with respect to the following
items, and if any abnormality is found, replace the
part.
• Smoothness of rotation
• Noise
• Abnormal external appearance, including dam-
age, rust, etc.
Legend
1. Spring
2. Insert
3. Clutch hub
4. Sleeve
N7A1197E
N7A1143E
Legend
1. Clutch hub
2. Sleeve
3. Ball
4. Block
5. Spring
N7A1199E
N7A1200E
MANUAL TRANSMISSION 7B-67
• Abnormal free play in thrust direction
10. Inspect the internal diameter of the gear.
• Measure the inside diameter of each gear us-
ing an inside dial gauge.
• If the measured value exceeds the limit, re-
place the gear.
11. Main shaft deflection
• Measure the deflection of the main shaft using
a dial gauge.
• If the measured value exceeds the limit, re-
place the main shaft.
Standard: 0.015 mm (0.000059 in)
Limit: 0.1 mm (0.00393 in)
12. Inspect the synchromesh system.
• Inspect the components, and repair light
stepped wear and damage using an oil stone or
a pencil grinder.
13. Clearance between block ring and dog gear
• Measure the clearance using a thickness
gauge.
• If the measured value exceeds the limit, re-
place the block gear.
Gear Internal Diameter, mm (in)
Standard
Limit
5th gear
44.009 — 44.025
(1.732 — 1.733)
44.065
(1.734)
3rd gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
2nd gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
1st gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
Reverse Gear
63.010 — 63.029
(2.480 — 2.481)
63.069
(2.483)
N7A1201E
Clearance between Block Ring and Dog Gear, mm
(in)
Standard
Limit
4th / 5th / Reverse
1.30 — 2.60
(0.051 — 0.102)
0.5 (0.019)
2nd / 3rd
1.00 — 2.50
(0.039 — 0.098)
0.5 (0.019)
1st
1.00 — 2.50
(0.039 — 0.098)
0.5 (0.019)
N7A1202E
N7A1203E
7B-68 MANUAL TRANSMISSION
14. Inspect the sliding part, spline part, inserting part
and insert groove of the clutch hub and sliding
sleeve for wear and damage.
15. Measure the free play in the direction of spline ro-
tation on the clutch hub external circumference.
• If the measured value exceed the limit, replace
the part.
16. Measure the clearance between the insert and
block ring groove using a caliper.
• If the measured value exceeds the limit, re-
place the insert and block ring.
17. Measure the clearance between the insert and
clutch hub using a thickness gauge.
• If the measured value exceeds the limit, re-
place the insert and clutch hub.
Legend
1. Block ring
2. Outside ring
3. Inside ring
Spline Free Play, mm (in)
Standard
Limit
0 — 0.05 (0 — 0.0019)
0.3 (0.0118)
N7A1204E
N7A1205E
Clearance between Insert and Block Ring Groove,
mm (in)
Standard
4th / 5th
3.46 — 3.76 (0.136 — 0.148)
Clearance between Insert and Clutch Hub, mm (in)
Standard
4th / 5th
0.01 — 0.21 (0.00039 — 0.00826)
N7A1206E
N7A1207E
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