Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1600

7B–36

MANUAL TRANSMISSION

Disassembly

1. Use a pair of snap ring pliers to remove the bearing

snap ring(1). (4X2)

2. Set the bearing remover J–37217 and puller J–37487

to the bearing and the mainshaft end to remove ball
bearing(2). (4X2)

262RW033

3. Remove bearing snap ring(3), speedometer drive

gear(4), clip(5), retainer snap ring(6) and retainer(7).
(4X2)

4. Set the retaining ring remover J–37222 and puller

J–37487 to the retainer(7) and the mainshaft end.
(4X4)

262RW031

5. Remove the retainer(7) together with the bearing(2)

and the oil seal collar(1). (4X4)
The universal puller may be used in place of the
retaining ring remover.

6. Remove thrust plate(8) and thrust washer and lock

ball(9).

7. Use a pair of snap ring pliers to remove reverse idler

gear snap ring(10).

226RS004

8. Remove the reverse idler gear assembly(11) from the

intermediate plate(30).

226RS005

9. Remove idle shaft pin(12), thrust washer(13), reverse

idler gear(14), and reverse idler shaft(15).

10. Use a pair of snap ring pliers to remove the snap

ring(16).

MANUAL TRANSMISSION

7B–37

11. Attach the bearing remover to the counter gear shaft.

Use the bearing remover to remove the ball
bearing(17) and the counter 5th gear(18).

226RS006

12. Remove counter reverse gear(19).
13. Remove 5th gear(20), 5th block ring(21), and needle

bearing (2 piece type) (22).

226RS007

14. Engage the 3rd–4th synchronizer with the 3rd gear.

Engage the 1st–2nd synchronizer with the 1st gear.
Attach the holding fixture J–37224 and base
J–3289–20 to the mainshaft and the counter gear.

226RS008

Use the mainshaft nut wrench J–37219 to remove the
mainshaft nut(23).

226RS009

7B–38

MANUAL TRANSMISSION

15. Use pry bars between the reverse gear(26) and

bearing plate(28) to remove the Rev–5th
synchronizer assembly(24) together with reverse
block ring(25) and reverse gear(26).

226RS010

16. Remove needle bearing(27).
17. Use the torx bit wrench J–37225(T45) to remove the

bearing plate and screw(28) from the intermediate
plate.

220RS014

18. Use the snap ring pliers(2) to remove the mainshaft

bearing snap ring(1) (29).

226RS011

19. Hold the snap ring open with the pliers.

Push the intermediate plate(30) toward the rear of the
transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair

Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly

1. Mesh the counter gear with the mainshaft assembly.

Install the holding fixture J–37224 and base
J–3289–20 to the mainshaft and the counter gear.

226RS012

MANUAL TRANSMISSION

7B–39

2. Place the holding fixture (with the mainshaft and the

counter shaft) in a vise.
Install the intermediate plate(30).

3. Install bearing snap ring(29).
4. Apply recommended thread locking agents

(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw(28).
Tighten the screws to the specified torque by using
torx bit wrench J–37225.

Torque: 15 N·m (11 lb ft)

220RS014

5. Install needle bearing(27), reverse gear(26), and

reverse block ring(25).

6. Assemble rev–5th synchronizer assembly(24) by

performing the following steps.
1. Turn the clutch hub face(1) toward the sleeve

groove(2) (rear side) on the outer circumference.

2. Check that the inserts(3) fit snugly into the block

ring insert grooves.

3. Check that the inserts springs(4) are fitted to the

inserts as shown in the illustration.

4. Check that the clutch hub(5) and the sleeve(6)

slide smoothly.

5. Install the synchronizer assembly to the

mainshaft.

The clutch hub face (with the heavy boss) must be
facing the reverse gear side.

226RS013

226RS049