Operation CHARM: Car repair manuals for everyone.
Home >> Isuzu Truck >> 1996 >> Trooper V6-3165cc 3.2L SOHC (6VD1) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Unit Repair >> Top Gear Shaft, Main Gear Shaft and Counter Gear Shaft

Top Gear Shaft, Main Gear Shaft and Counter Gear Shaft




TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR SHAFT

DISASSEMBLY
1. Top gear shaft snap ring
- Use a pair of snap ring pliers to remove the snap ring.
2. Top gear shaft
3. Ball bearing




- Use a bench press and the bearing remover to remove the ball bearing.
Bearing remover : J-22912-01
4. Needle bearing
5. Top block ring
6. Mainshaft snap ring




- Use a pair of snap ring pliers to remove the snap ring.
7. 3rd-4th synchronizer assembly




- Use a bench press and the bearing remover to remove the synchronizer assembly as a set.
Bearing remover : J-22912-01
- Disassemble the synchronizer assembly
(1) Springs
(2) Sleeve
(3) Clutch hub
(4) Inserts
8. 3rd block ring
9. 3rd gear
10. Needle bearing
11. Needle bearing collar
12. Mainshaft ball bearing
13. 1st gear thrust bearing
14. 1st gear




- Use a bench press and the bearing remover to remove the ball bearing.
Bearing remover : J-22912-01
15. 1st inside ring
16. 1st outside ring
17. 1st block ring
18. Needle bearing
19. Clutch hub snap ring




- Use a pair of snap ring pliers to remove the snap ring.
20. 1st-2nd synchronizer assembly
21. 2nd block ring
22. 2nd outside ring
23. 2nd inside ring
24. 2nd gear




- Use a bench press and the bearing remover to remove the 2nd gear together with synchronizer assembly.
Bearing remover : J-22912-01
- Disassemble the synchronizer assembly
(1) Springs
(2) Sleeve
(3) Clutch hub
(4) Inserts
25. Needle bearing
26. Mainshaft
27. Bearing snap ring
28. Front roller bearing




- Use a bench press and the bearing remover to remove the front roller bearings.
Bearing remover : J-22912-01
29. Center roller bearing
30. Counter gear shaft

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during inspection.




Block Ring And Dog Teeth Clearance:




BLOCK RING AND DOG TEETH CLEARANCE
- Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the block ring must be replaced.




Block Ring And Dog Teeth Clearance:




1ST-2ND SYNCHRONIZER (3-CONE)
- Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the 1st-2nd synchronizer assembly must be replaced.




Block Ring And Insert Clearance:




BLOCK RING AND INSERT CLEARANCE
- Use a vernier caliper or thickness gauge to measure the clearance between the block ring and the insert.
If the measured value exceeds the specified limit, the block ring and the insert must be replaced.




Clutch Hub And Insert Clearance:




CLUTCH HUB AND INSERT CLEARANCE
- Use a thickness gauge to measure the clearance between the clutch hub and the insert ring.
If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.




MAINSHAFT RUN-OUT
- Install the mainshaft to V-blocks.
- Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.

Mainshaft run-out Limit : 0.05 (0.0020) mm (in)




Gear Inside Diameter:




GEAR INSIDE DIAMETER
- Use an inside dial indicator to measure the gear inside diameter.
If the measured value exceeds the specified limit, the gear must be replaced.




Idler Gear And Idler Gear Shaft Clearance:




REVERSE IDLER GEAR AND IDLER GEAR SHAFT CLEARANCE
- Use a micrometer to measure the idler gear shaft diameter.
- Use an inside dial indicator to measure the idler gear inside diameter.
- Calculate the idler gear and idler gear shaft clearance.

Idler gear inside diameter-idler gear shaft diameter = idle gear and idler gear shaft clearance.

If the measured value exceeds the specified limit, the idle gear and/or the idler gear shaft must be replaced.




Clutch Hub Spline Play:




CLUTCH HUB SPLINE PLAY
- Set a dial indicator to the clutch hub to be measured.
- Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the clutch hub must be replaced.

BALL BEARING PLAY
- Use a dial indicator to measure the ball bearing play.

Ball bearing play Limit : 0.2 (0.008) mm (in)




REASSEMBLY
30. Counter gear shaft
29. Center roller bearing
- Apply engine oil to the bearing inner and outer circumferences.




- Install the roller bearing in the proper direction.

NOTE: Check that outer race moves only in the direction of arrow.




28. Front roller bearing
- Use bearing installer to install the front roller bearing inner race to the counter gear shaft.
- Install the outer race and roller assembly. The snap ring groove must be facing the transmission front side.
- Use bearing installer to install the ring.
Bearing installer : J-35283
27. Bearing snap ring
26. Mainshaft
25. Needle bearing
24. 2nd gear
- Apply engine oil to the needle bearing and the 2nd gear thrust surfaces.




- Install the needle bearing and the 2nd gear to the mainshaft.
The 2nd gear dog teeth must be facing the transmission rear side.




23. 2nd inside ring
22. 2nd outside ring
21. 2nd block ring
- Apply engine oil to the synchronizer ring surfaces.







20. 1st-2nd synchronizer assembly
1. Check that the inserts (3) fit snugly into the block ring insert grooves.
2. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing the 2nd gear side.
19. Clutch hub snap ring




- Select the snap ring which will provide the minimum clearance between the 1st-2nd clutch hub and the snap ring.

Clutch hub and snap ring clearance standard : 0-0.1 (0-0.004) mm (in)




Snap Ring Availability:




There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness.




- Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the mainshaft snap ring groove.




18. Needle bearing
17. 1st block ring
16. 1st outside ring
15. 1st inside ring
14. 1st gear
- Apply engine oil to the needle bearing, 1st gear thrust surfaces and synchronizer ring friction surfaces.
- Install the needle bearing and the 1st gear to the mainshaft
The 1st gear dog teeth must be facing the transmission front side.
13. 1st gear thrust bearing




- Install the thrust bearing and the race to the mainshaft.
The thrust bearing side must be facing the transmission front side.
12. Mainshaft ball bearing
11. Needle bearing collar
- Apply engine oil to the ball bearing and the mainshaft.
- Install the ball bearing and collar to the mainshaft.
The ball bearing snap ring groove must be facing the transmission rear side.




- Use a bench press to slowly force the collar into place.
Installer : J-6133-01
10. Needle bearing
9. 3rd gear
- Apply engine oil to the needle bearing and the 3rd gear thrust surfaces.




- Install the needle bearing and the 3rd gear to the mainshaft.
The 3rd gear dog teeth must be facing the transmission front side.
8. 3rd block ring







7. 3rd-4th synchronizer assembly
1. Check that the inserts (3) fit snugly into the block ring insert grooves.
2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing the 3rd gear side.
6. Mainshaft snap ring




- Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.




Snap Ring Availability:




There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness.
- Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the mainshaft snap ring groove.
5. Top block ring
4. Needle bearing
- Apply grease to the bearing inner and outer circumferences.
3. Ball bearing
2. Top gear shaft
1. Top gear shaft snap ring




- Use a bench press to install the top gear shaft ball bearing to the mainshaft.
The snap ring groove must be facing the transmission front side.
- Use a pair of snap ring pliers to install the snap ring to the bearing.
pro multis · About Operation CHARM