Isuzu Trooper (1998-2002 year). Manual — part 805
7B–30 MANUAL TRANSMISSION
20. Remove the top gear shaft.
1. Remove the top gear shaft from mainshaft.
NOTE: Don’t fall needle roller bearing.
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2. Remove the 4th block ring and roller bearing.
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21. Disassemble the top gear shaft assembly.
1. Check for wear or damage.
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2. Remove the front bearing shaft snap ring.
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MANUAL TRANSMISSION
7B–31
3. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the bearing.
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22. Remove the mainshaft.
1. Remove mainshaft bearing snap ring.
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2. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift side.
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3. Remove the intermediate plate from a vise.
4. Remove the mainshaft, 1st-2nd shift arm and
3rd-4th shift arm.
226RW014
7B–32 MANUAL TRANSMISSION
23. Disassemble the mainshaft assembly.
1. Inspect each gear thrust clearance.
1. Using thickness gauge, inspect thrust
clearance (1st gear, 3rd gear).
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2. Mount the mainshaft through the aluminum
plate in a vise.
3. Using a dial indicator, measure each gear
thrust clearance.
Gear
Standard Clearanse
1st
0.15 – 0.45 mm (0.0059 – 0.0177 in)
2nd
0.10 – 0.25 mm (0.0039 – 0.0098 in)
3rd
0.10 – 0.25 mm (0.0039 – 0.0098 in)
226RW070
2. Inspect each gear radial clearance
1. Using a dial indicator, measure the radial
clearance of each gear.
Gear
Standard Clearanse
1st
0.020 – 0.074 mm (0.00078 – 0.00291 in)
2nd
0.015 – 0.068 mm (0.00059 – 0.00268 in)
3rd
0.015 – 0.068 mm (0.00059 – 0.00268 in)
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3. Using 2 screwdrivers and hammer, tap out the
snap ring.
226RW053
MANUAL TRANSMISSION
7B–33
4. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).
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5. Remove following parts from mainshaft.
1. Synchronizer assembly (1).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).
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6. Using 2 screwdrivers and hammer, tap out snap
ring.
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7. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. Clutch hub No.1 assembly (1).
2. Synchronizer assembly (2).
3. 2nd gear (3).
4. 2nd gear needle roller bearing (4).
226RW198
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