Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1595

7B–16

MANUAL TRANSMISSION

Transmission Case

Major Component (4X2)

220RW050

Legend

(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Rring

(7) Speedometer Sensor and Speedometer Driven

Gear

(8) Gear Control Box Assembly
(9) Rear Cover with Oil Seal

(10) 1–2 and 3–4 Indicator Switch, Pin, and Ball

(11) Intermediate Plate with Gear Assembly

(12) Transmission Case

MANUAL TRANSMISSION

7B–17

Disassembly

1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case

and drain the lubricant.

3. Remove the clutch release bearing(1) from the

transmission case.

201RS020

4. Remove the snap pin.

Remove the shift fork pin and shift fork(2) from the
fulcrum bridge.

201RS021

5. Remove the fulcrum bridge bolts.

Remove the fulcrum bridge(3) from the transmission
case.
Remove the front cover(4) and gasket from the
transmission case.

201RS022

6. Remove snap ring(5) fixing counter front bearing.
7. Use a pair of snap ring pliers to remove the snap

ring(6) fixing top gear bearing.

226RS001

8. Remove the speedometer sensor(7).

Remove the plate(7).
Remove the driven gear bushing and driven gear(7).

NOTE: Apply a reference mark to the driven gear bushing
before removal.

9. Remove gear control box assembly(8).

10. Remove the rear cover assembly from the

transmission case.

11. Remove 1–2 and 3–4 indicator switch(10), pin(10)

and ball(10).
Remove intermediate plate with gear assembly(11)
from transmission case(12).

7B–18

MANUAL TRANSMISSION

Reassembly

1. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transmission case(12),
intermediate plate(11) and rear cover(9) fitting
surfaces.

2. Install the intermediate plate with gear assembly(11)

to the transmission case(12).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.

3. Tighten the transmission rear cover bolts to the

specified torque.

Torque: 37 N·m (27 lb ft)

NOTE:

Notes When Tightening the Bolt:

D

After cleaning the bolt hole, dry it thoroughly with air.

D

After cleaning the screw face of a removed bolt or new
one, dry it thoroughly.  Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening it.

4. Install a new gasket and gear control box

assembly(8).
Install the harness clips and brackets and then tighten
four new gear control box bolts to the specified
torque.

Torque: 20 N·m (14 lb ft)

261RW043

5. Install the O-ring(4) to the speedometer driven gear

bushing(3).
Install the driven gear to the speedometer driven gear
bushing(3).

6. Install the speedometer driven gear assembly(7) to

the transmission rear cover(9).
Install the plate(1) to the transmission rear cover(9).

Torque: 15 N·m (11 lb ft)

7. Install the speedometer sensor(7).

Torque: 27 N·m (20 lb ft)

225RW008

MANUAL TRANSMISSION

7B–19

8. Install top gear bearing snap ring(6) and counter front

bearing snap ring(5).

D

Use a pair of snap ring pliers to install the snap rings
to the mainshaft and countershaft.

D

The snap rings must be fully inserted into the
bearing snap ring groove.

9. Install front cover (with oil seal) (4).

Front Cover Oil Seal Replacement

D

Remove the oil seal from the front cover.

D

Apply engine oil to a new oil seal outer
circumference.

D

Apply recommended grease to the oil seal lip.

D

Use the oil seal installer J–26540 to install the oil
seal to the front cover.

220RS008

10. Install a new packing and front cover(4) to the

transmission case.

NOTE: Take care not to damage the oil seal.

Notes When Tightening the Bolt:

D

After cleaning the bolt hole, dry it thoroughly with air.

D

After cleaning the screw face of a removed bolt or new
one, dry it thoroughly.  Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six new front cover bolts to the specified
torque.

Torque: 25 N·m (18 lb ft)

11. Install the fulcrum bridge(3) to the transmission case.

Tighten three fulcrum bridge bolts to the specified
torque.

Torque: 38 N·m (28 lb ft)

220RS009

12. Apply grease to the pin hole inner circumferences and

thrust surfaces.
Attach the shift fork(2) to the fulcrum bridge(3) by
inserting the shift fork pin from the bottom side of the
fulcrum bridge.
Install the washer and snap pin.

201RS018