Inspection and Repair

Note: Isuzu manuals address both the Automatic and Manual transmission transfer case procedure in the same repair section. Where there is a distinction between Automatic and Manual transmissions concerning transfer case it is noted in the article or image.



INSPECTION AND REPAIR

Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection.

Wash all parts thoroughly in clean solvent. Be sure all old lubricant, metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.

GEARS

Inspect all gear teeth for signs of excessive wear or damage and check all gear splines for burrs, nicks, wear or damage. Remove minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.





Gear inside diameter

Diameter 48.10 (1.893) mm (in.)






Play in splines


Play 0.2 (0.0079) mm (in.)




BEARINGS

Inspect the condition of all needle, and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to bearings.

NOTE:

Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers.

Lubricate bearings with a light oil and check them for roughness by slowly turning the race by hand.





Measure the ball bearing play. Replace bearings if not within the specifications shown


Limit 0.2 (0.0079) mm (in.)


SYNCHRONIZERS (M/T MODEL ONLY)

The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled.

Clean synchronizer components with clean solvent and air dry.

Inspect the components for the following:

Teeth for wear scuffs, nicks, burrs or breaks

Keys and springs for wear, cracks or distortion, replace if these conditions are present.

If scuffed, nicked or burred conditions cannot be corrected with a soft stone or crocus cloth, replace the component.





Measure the clearance between block ring and inserts. Replace components if not within specifications shown

Clearance 4.9 (0.193) mm (in.)





Measure the clearance between blocker ring and gear. Replace components if not within specifications shown

Limit 0.8 (0.031) mm (in.)

NOTE: Replace gear assembly if evidence of engine braking can be seen on the dog teeth.



DETENT SPRINGS





Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.

Measure the spring length. Replace springs if not within the specifications shown

Detent Spring 26.2 (1.03) mm (in.) or less
Interlock Pin 1.53 (0.060) mm (in.) or less





Measure the spring tension Replace springs if not within the specifications shown


Compressed height 20 mm (0787 in)
Spring tension 87-97 N (19.6-21.8 lb)


SHIFT FORKS


Inspect the shift forks, shafts and levers for wear, distortion or scoring. Replace if these conditions are present.




Measure shift fork pad thickness and replace if thinner than the specifications shown
Limit 9.0 (0.354) mm (in.)





In case of M/T model, measure clearance between clutch hub and inserts
Limit 0.4 (0.016) mm (in.)


MAINSHAFT

Measure the run-out of the mainshaft and replace with a new one if reading exceeds limit.

Limit 0.05 (0.0019) mm (in.)