Isuzu Rodeo UE. Service manual — part 504
7B–48
MANUAL TRANSMISSION
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
MANUAL TRANSMISSION
7B–49
7. Mesh the 1st–2nd and 3rd–4th synchronizers with
both the 1st and 3rd gears (double engagement).
226RS015
This will prevent the mainshaft from turning.
8. Install the new mainshaft hub nut.
Use the mainshaft nut wrench J–37219 to tighten the
mainshaft nut(23) to the specified torque.
Torque: 137 N·m (101 lb ft)
226RS016
9. Use a punch to stake the mainshaft nut.
226RW153
10. Install needle bearing(22), 5th block ring(21), and 5th
gear(20).
11. Apply engine oil to the counter reverse gear(19) and
the reverse gear(26).
Install the counter reverse gear(19) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.
226RW151
7B–50
MANUAL TRANSMISSION
12. Install the counter 5th gear(18) to the transmission.
226RS019
13. Install ball bearing(17) and bearing snap ring by
performing the following steps:
f
Select the snap ring which will provide the minimum
clearance between the ball bearing and the snap
ring.
226RS020
f
There are six snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.
226RS021
Ball Bearing and Snap Ring Clearance
Standard: 0–0.15 mm (0–0.0059 in)
Snap Ring Availability
Thickness
Color Coding
1.1 mm (0.043 in)
White
1.2 mm (0.047 in)
Yellow
1.3 mm (0.051 in)
Blue
1.4 mm (0.055 in)
Pink
1.5 mm (0.059 in)
Green
1.6 mm (0.063 in)
Brown
f
Use a pair of snap ring pliers to install the snap
ring(16) to the counter gear shaft.
The snap ring must be fully inserted into the counter
gear shaft snap ring groove.
14. Assemble reverse idler shaft(15), reverse idler
gear(14), thrust washer(13), and idle shaft pin(12)
into reverse idler gear assembly(11).
MANUAL TRANSMISSION
7B–51
15. Select reverse idler gear snap ring(10) which will
provide the minimum clearance between the
intermediate plate(30) and the snap ring(10).
226RS022
f
There are three snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 – 0.15 mm (0 – 0.0059 in)
Snap Ring Availability
Thickness
Color Coding
1.2 mm (0.047 in)
White
1.3 mm (0.051 in)
Yellow
1.4 mm (0.055 in)
Blue
226RS021
f
Use a pair of snap ring pliers to install the snap ring
to the reverse idler shaft.
The snap ring must be fully inserted into the reverse
idler shaft snap ring groove.
16. Install thrust washer and lock ball(9) by performing
the following steps:
f
Use a thickness gauge to measure the clearance
between the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 – 0.25 mm (0.004 – 0.010 in)
f
Measure clearance “A” as shown in the figure.
226RS023
f
Select appropriate thrust washer from chart.
f
There are four thrust washer sizes available.
f
The thrust washers are color coded to indicate their
thickness.
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