Isuzu N-Series. Service manual - part 862

 

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Isuzu N-Series. Service 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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