Service Procedure

Follow the 5 speed transmission disassembly steps in a 1984 Isuzu Workshop Manual. Continue disassembly up to and including removal of the 5th gear thrust washer. Then proceed as follows.

1. Measure thrust distance on end shaft from face of 5th gear (be sure it is fully forward) to the front edge of the main shaft end bearing snap ring groove. (See fig. 1)
2. Locate distance measured in #1 above on the chart below. Then select the proper thrust distance piece from the repair parts package.

MEASUREMENT PART MARKING PART NUMBER

- 56.17 1 one RED dot 8-94158-367-0
56.18 - 56.37 2 two RED dots 8-94158-368-0
56.38 - 56.57 3 three RED dots 8-94158-369-0
56.58 - 56.77 1 one GREEN dot 8-94158-370-0
56.78 - 56.97 2 two GREEN dots 8-94158-371-0
56.98 - 3 three GREEN dots 8-94158-372-0






3. Install thrust distance piece on end shaft immediately behind 5th gear. Align thrust distance spacer using the original thrust washer ball. (See fig. 2, 3)



4. Install one part number 8-94158-435-0 snap ring from repair kit into snap ring groove immediately to the rear of thrust distance spacer. (See fig. 4)



5. Press on original end shaft end bearing with the sealed side of the bearing facing rearward. Check distance between thrust distance spacer and snap ring installed in #4 above. Clearance should be 0.1 - 0.35 mm. (Sec fig. 5)



6. Reinstall original speedometer drive gear bearing spacer. (Sec fig. 6)
7. Replace the original nylon speedometer drive gear with a steel drive gear from the kit using the following chart: (See fig 6)

PART CURRENT DRIVEN APPLICABLE
NUMBER PART NO. GEAR T0

9-33371-604-1 8-94223-037-1 16, 17, 18 PF, JR
9-33371-611-0 8-94223-036-1 17, 18
KB,PF



8. Secure the drive gear to the shaft using the key provided. (Sec fig. 7)



9. Measure distance from rear of speedometer drive gear to rear edge of snap ring groove. Use the proper snap ring from the chart below to achieve a remaining clearance in the snap ring groove of between 0.0 and 0.15 mm. (Sec fig. 8)
THICKNESS
PART NUMBER +0.05

8-94158-435-0 1.5
8-94158-436-0 1.6
8-94158-437-0 1.7
8-94158-438-0 1.8
10. Follow workshop manual procedure for completion of transmission reassembly.