Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1592

7B–4

MANUAL TRANSMISSION

Diagnosis

Condition

Possible cause

Correction

Abnormal noise

Flywheel pilot bearing worn

Replace

Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)

Replace

Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)

Replace

Splines worn (Mainshaft,
synchronizer clutch hub)

Replace

Gear or bearing thrust face seized

Replace

Lack of backlash between meshing
gears

Replace

Hard Shifting

Improper clutch pedal free play

Readjust

Change lever sliding portions worn

Repair or replace Regrease

Shift block, shift rod and/or control
box sliding faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Synchronizer parts worn

Replace

Walking or Jumping out of gear

Detent ball worn

Replace

Detent spring weakened or broken

Replace

Shift rod and/or control box sliding
faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Bearings worn or broken

Replace

Splines worn (Mainshaft,
synchronizer hub)

Replace

Synchronizer spring weakened or
broken

Replace

Oil leakage

Loose drain plug(s) and/or filler
plug(s)

Tighten Replenish oil

Defective or improperly installed
gasket(s)

Replace

Oil seal worn or scratched

Replace

MANUAL TRANSMISSION

7B–5

Rear Oil Seal (4X2)

Disassembled View

220RY00016

Legend

(1) Rear Propeller Shaft
(2) Rear Oil Seal

Removal

1. Raise and support vehicle with suitable jack stands.
2. Remove propeller shaft flange yoke bolts and nuts at

the differential side.
Remove propeller shaft from the transmission main
shaft spline.

3. Use a screwdriver to pry the rear oil seal from the rear

cover.

Installation

1. Install a new oil seal(2) or (3) using the installer

J–29769.

220RS044

2. Insert the splined yoke into the transmission

mainshaft spline.

3. Install the propeller shaft flange yoke to the drive

pinion flange.

Torque: 63 N·m (46 lb ft)

4. Check transmission fluid level.
5. Lower vehicle.

7B–6

MANUAL TRANSMISSION

Transmission

Disassembled View

220RW040

Legend

(1) Gear Control Lever Knob
(2) Transfer Control Lever Knob
(3) Center Console
(4) Grommet Assembly
(5) Gear Control Lever and Transfer Control Lever
(6) Transfer Protector
(7) Fairing Plate
(8) Rear Propeller Shaft
(9) Front Propeller Shaft

(10) Center Exhaust Pipe

(11) Fuel Pipe Heat Protector

(12) Harness Clamp
(13) Harness Heat Protector
(14) Slave Cylinder
(15) Dust Cover
(16) Rear Mount Nut
(17) Third Crossmember
(18) Starter
(19) Flywheel Undercover
(20) Transmission Retaining Nut and Bolt
(21) Transmission

MANUAL TRANSMISSION

7B–7

Removal

NOTE: Befor removing transmission assembly(4X4)
from vehicle, change the transfar mode to 2WD using the
4WD push button on dash panel.

1. Disconnect battery ground cable.
2. Remove gear control lever knob(1).
3. Remove transfer control lever knob(2) (4X4).
4. Remove lower cluster assembly.

740RW021

5. Remove rear console.

256RW005

6. Remove center console(3).

F07RW023

7. Remove grommet assembly(4).

262RW027