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Home >> Isuzu >> 2002 >> Trooper S, 4WD, Part Time >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - Ar-5 5-Speed >> Transmission Disassembly

Transmission Disassembly

  1. Remove drain plug and filler plug. Remove clutch release bearing from front cover. Remove split pin, then remove shift fork. Remove back-up light switch and 1st-2nd switch. Remove 9 bolts and remove clutch housing by tapping with a plastic hammer.
  2. Remove 6 bolts and remove shift control box and gasket from top of transfer case adapter. See Fig 3 . Remove hex-head plug from rear of transfer case adapter, above mainshaft. Through shift control box opening, drive out spring pin from gear control rod. Thread an M8 x 1.25 bolt into gear control rod at hex-head plug opening. Pull gear control rod from case.
  3. Remove 10 bolts holding transfer case adapter onto transmission case. Cover mainshaft splines with tape and lightly tap transfer adapter case until free of transmission case. Use care not to lose spring pin.
  4. UsingTorx bit and Allen wrench, remove plugs from sides of transfer case adapter. With punch, drive out slotted spring pin from inside of plug opening, and remove reverse restrict pin from rear on transfer case adapter.
  5. Remove oil receiver pipe and oil seal. Remove 8 front cover bolts, and carefully tap front cover to remove. Mount front cover into soft-jawed vise, and use screwdriver to carefully pry out oil seal.
  6. With front cover removed, remove snap rings from input shaft and countergear shaft. With plastic hammer, carefully tap transmission case intermediate plate and remove mainshaft and gear assembly.
  7. Mount intermediate plate into soft-jaw vise and drive slotted pin out from side of 5th shift arm. See Fig 2 .
    Fig 1: Exploded View Of Transmission Gear Components
    G99H04308Courtesy of ISUZU MOTOR CO.
    Fig 2: Exploded View Of Shift Components
    G99J04309Courtesy of ISUZU MOTOR CO.
    Fig 3: Exploded View Of Transmission Case Components
    G99B04310Courtesy of ISUZU MOTOR CO.
  8. Remove bolt from 1st-2nd shift arm. Remove bolt from 3rd-4th shift arm. See Fig 2 .
  9. Remove snap ring. Use Gear Puller (J-42794) and Attachment (J-42988) to remove 5th gear spline piece. See Fig 1 . Remove hub sleeve No. 3, block ring set, counter 5th gear, bearing and 5th shift arm. Remove synchronizer pull ring, synchronizer cone ring, and synchronizer outer ring from hub sleeve No. 3. See Fig 4 . Remove 3 inserts and compression springs.
    Fig 4: Disassembling/Reassembling Hub Sleeve No. 3
    G99D04311Courtesy of ISUZU MOTOR CO.
  10. Remove thrust washer from countergear shaft, then remove pin from shaft. Remove 4 bolts and remove mainshaft bearing retainer. Pull countergear shaft forward, and remove reverse idle gear from opposite side of intermediate plate.
  11. Remove countergear shaft center bearing snap ring. Remove countergear shaft using Center Bearing Remover (J-42795) and Attachment (J-42988). Remove countergear from intermediate plate. Disassemble countergear shaft assembly by removing snap ring and pressing off bearing.
  12. Using care not to drop needle bearing, remove input shaft from mainshaft. Remove 4th block ring and roller bearing. Remove front bearing snap ring and press off bearing.
  13. Remove mainshaft bearing snap ring. Lightly tap 5th-reverse shift rod from back side of intermediate plate, then remove mainshaft, 1st-2nd shift arm, and 3rd-4th shift arm from intermediate plate. With feeler gauge, measure thrust clearance at 1st gear and 3rd gear. Record measurements. With mainshaft upright in soft-jaw vise, use a dial indicator with tip between each gear set to measure gear thrust clearance. See MAINSHAFT GEAR THRUST CLEARANCE  table.
  14. Remount dial indicator with tip positioned onto outer edge of each gear, and measure radial clearance of each gear. See MAINSHAFT GEAR RADIAL CLEARANCE  table.
    MAINSHAFT GEAR THRUST CLEARANCE

    Gear In. (mm)
    1st .006-.018 (.15-.45)
    2nd .004-.010 (.10-.25)
    3rd .004-.010 (.10-.25)
    MAINSHAFT GEAR RADIAL CLEARANCE

    Gear In. (mm)
    1st .0008-.0029 (.020-.074)
    2nd .0006-.0027 (.015-.068)
    3rd .0006-.0027 (.015-.068)
  15. Remove snap ring from mainshaft bearing. Use bearing separator and press to remove 5th gear, mainshaft bearing, 1st gear thrust washer and 1st gear. From mainshaft, remove synchronizer assembly, 1st gear thrust washer pin, 1st gear needle roller bearing and 1st gear bearing spacer. Tap out snap ring in front of clutch hub No. 1, and remove clutch hub No. 1 assembly, synchronizer assembly, 2nd gear and 2nd gear bearing.
  16. Remove reverse gear from clutch hub No. 1. Push insert against springs, and remove 3 synchronizer inserts and compression springs. Remove snap ring from clutch hub No. 2. Using a press, remove clutch hub No. 2, 3rd block ring, 3rd gear and 3rd gear needle bearing. Using screwdriver, remove 2 insert springs, hub sleeve No. 2 and 3 hub sleeve inserts.
  17. Mount intermediate plate into soft-jaw vise. With plastic hammer, tap 5th-reverse shift rod from back side of plate, then remove shift parts and interlock parts. Using Torx socket wrench, remove 4 plugs from side of intermediate plate. Using magnet, remove springs and balls from bores. Remove snap rings from each shift fork rod. Pull 3rd-4th shift rod out from rear. Use a magnet to remove interlock pin and straight pin from plug opening. Repeat process for 1st-2nd shift rod.
  18. Remove 2 snap rings from 5th-reverse shift rod. Pull 5th-reverse shift rod out from front of intermediate plate. Using magnet, remove interlock pin from intermediate plate and ball from reverse shift arm No. 1. Pull out reverse shift rod, reverse shift arm No. 1 and reverse shift arm No. 2 at same time while removing from intermediate plate.
  19. Pull reverse shift rod from reverse shift arm. Using magnet, remove ball and spring from reverse shift arm No. 1. Remove reverse shift arm No. 2 "E" ring. Remove reverse shift arm No. 2 from reverse shift arm No. 1. Remove 2 bolts, and remove shift arm bracket from intermediate plate.
  20. Install counter 5th gear thrust washer pin, thrust washer, needle bearing and counter 5th gear onto countergear shaft. Hold assembly in soft-jaw vise. Using dial indicator, place tip on side of gear. Measure gear radial (thrust) clearance. Clearance should be .0027-.0006" (.015-.068 mm). Remove gear from counter shaft and measure inside diameter of gear. Diameter should be 1.4967-1.4976" (38.02-38.04 mm).
  21. Measure 5th-reverse shift arm thickness. Thickness should be .402" (10.2 mm). Measure center groove of hub sleeve No. 3. Calculate clearance between hub sleeve No. 3 and shift arm. Groove dimension should be .413" (10.5 mm), and clearance should be .010-.033" (.25-.84 mm).
  22. Using feeler gauge, measure clearance between counter 5th gear spline piece and reverse block ring. Clearance should be .028-.067" (.7-1.7 mm).
  23. Mount reverse idler gear and shaft horizontally onto holder blocks. With dial indicator tip touching outer edge of reverse idler gear, measure radial clearance. Clearance should be .0016-.0032" (.040-.082 mm). If radial clearance exceeds maximum, measure gear inside diameter and shaft diameter. Gear diameter should be .9465-.9473" (24.04-24.06 mm). Shaft diameter should be .9441-.9449" (23.98-24.00 mm).
  24. Using feeler gauge, measure reverse shift arm No. 2 thrust clearance between reverse idler gear and shift arm (both in installed position). Clearance should be .002-.014" (.05-.35 mm).
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