Isuzu Trooper - Isuzu Trooper
1. Maintenance instruction
2. Maintenance
3. Engines
4. System of decrease in toxicity
5. Fuel system
6. Transmission and running gear
   6.1. Manual transmission
      6.1.1. Backing signal switch
      6.1.2. Speedometer reducer
      6.1.3. Removal and installation of the manual transmission
      6.1.4. 4-staged the check point for rear wheel drive cars
      6.1.5. 5-staged check point of the Trooper/Bighorn cars of early release, 4х4
      6.1.6. 5-staged check point of cars of late release, 4х4
      6.1.7. 5-staged Borg-Warner check point of the Rodeo/Passport cars
      6.1.8. Coupling
   6.2. Automatic transmission
   6.3. Running gear
7. Suspension bracket and steering
8. Brake system
9. Body
10. Body electric equipment
11. Diagnostics of malfunctions
12. Electrical circuitries





Isuzu Trooper>> Transmission and running gear>> Manual transmission>> 4-staged the check point for rear wheel drive cars

6.1.4. 4-staged the check point for rear wheel drive cars

GENERAL INFORMATION

Details 4-staged check point

11 – primary, secondary, intermediate shaft of the check point and block of gear wheels

1 – check point control lever case
2 – release bearing and holder of the bearing
3 – coupling switching off lever
4 – forward epiploon of the check point

 

5 – spring washer
6 – lock ring
7 – the conducted speedometer drive gear wheel
8 – backing signal switch
9 – back cover
10 – epiploon

Preliminary remarks

Before dismantling absolutely wash up a check point case, without allowing dirt hit inside. Before check all details of the check point should be washed out and dried.

At assembly of details of the mechanism of the check point grease all epiploons, needle bearings (for their deduction) with SAE-30 oil or technical vaseline. Use of jellied lubricant for bearings of naves is not allowed. All epiploons and consolidations are made of neoprene rubber therefore it is forbidden to wash out them in solvents. Before assembly carefully clear all female threads and oil them gearbox. The case is cast from aluminum alloy therefore at a wraparound in a case of bolts their distortion is not allowed, otherwise a thread will be stripped. When using old spring rings unclench internal lock rings, and draw in external lock rings.

Dismantling

PERFORMANCE ORDER
Dismantling of the check point (1st stage)
1. Remove the case of the mechanism of management of the check point, get the lever.
2. Remove the holder of a forward epiploon, an epiploon and a spring washer.
3. Remove a lock ring of the forward bearing.
4. Remove a reducer of a speedometer and the switch of a signal of a backing.
5. Remove a back cover and an epiploon.
6. Get a main shaft, secondary and intermediate shaft assembled with gear wheels.
Dismantling of the check point (2nd stage)
7. Get persistent rings of an intermediate gear wheel of a backing.
8. Turn off a bolt of a shaft of an intermediate gear wheel, remove a lock plate and get a backing gear wheel shaft.
9. Remove a persistent plate, a spring and a ball of a clamp.
10. Remove a rod and a fork of inclusion of a backing.
11. Get the blocking crackers and remove rods of inclusion of 4/3 and 1/2 transfers.
12. Remove forks of inclusion of 4/3 and 1/2 transfers.
13. Get a side pin of a partition.
14. Remove an external spring ring of an intermediate gear wheel of a backing, a speedometer drive gear wheel, a spline, an internal lock ring and a gear wheel.
15. Turn off a samopodzhimny nut of a secondary shaft and remove a washer.
16. Turn off a samopodzhimny nut of an intermediate shaft and remove a washer.
17. Remove an internal partition from shaft.
18. Get a lock ring of the bearing of an intermediate shaft.
19. Get a lock ring of the bearing of a secondary shaft.
20. Remove from an intermediate shaft: leading gear wheel of a backing, plug, back bearing and needle bearings.
21. Remove a main shaft, a vypressuyta the bearing and get needle bearings.
22. Remove the blocking ring of the synchronizer of the 3rd and 4th transfers, a forward lock ring of a shaft, a nave and the coupling of the synchronizer of the 3rd and 4th transfers.
23. Remove the blocking ring of the synchronizer of the 3rd transfer, the conducted gear wheel of the 3rd transfer and the needle bearing.
24. Remove the bearing of a secondary shaft, a persistent washer, the conducted gear wheel of the 1st transfer, the needle bearing and the plug.

25. Remove from a secondary shaft the blocking ring of the synchronizer 1 and 2nd of transfers, a nave and the coupling of the synchronizer 1 and 2nd of transfers blocking a ring of the synchronizer of the 2nd transfer, the conducted gear wheel of the 2nd transfer and the needle bearing.


Check

PERFORMANCE ORDER
1. Check thickness of forks of inclusion of transfers in the place of contact with the synchronizer coupling. Thickness of a fork of inclusion of the 1st and 2nd transfers – 7,8–7,9 mm, the 3rd and 4th transfers – 7,1–7,2 mm, a fork of turning on of the reverse gear – 6,8–6,9 mm.
2. Measure by a caliper length of springs of clamps. Length of springs of a clamp of the 1st, 2nd, 3rd and 4th transfers – 27,5–30,5 mm, the reverse gear of 24,7-27,7 mm.
3. Check elasticity of a spring which has to be for clamps of the 1st, 2nd, 3rd and 4th transfers of 4,0-4,2 kgfs and for clamps of the reverse gear of 6,3-6,7 kgfs.
4. Check a gap between the blocking rings and an end face of a gear wreath of gear wheels. A standard gap – 0,8–1,5 mm.
5. Check a gap between the blocking rings and crackers. A standard gap – 3,51 - 4,00 mm.
6. Check a gap between a nave of the synchronizer and crackers. The gap has to be within 0,01–0,3 mm.
7. Check a beating of a secondary shaft which should not exceed 0,03 mm.
8. Measure the internal diameter of gear wheels. Norm: for gear wheels of the 1st transfer and a backing of 45,0-45,1 mm, for gear wheels of the 2nd and 3rd transfers – 41,0–41,1 mm.
9. Check a gap between the plug and shaft of an intermediate gear wheel of a backing (norm of 0,041-0,15 mm).
10. Check a side play in gearing of the conducted and conducting gear wheels. The side play in gearing of gear wheels with the 1st on the 4th transfer has to be within 0,0–0,20 mm.
11. Replace details which do not meet the specified requirements.

Assembly of the synchronizer (4-staged check point)

1 – spline

2 – spring

3 – coupling


Assembly of the synchronizer 1 and 2nd of transfers (4-staged check point)

1 – big facet

2 – small facet

3 – forward

4 – back


Assembly of the synchronizer of the 3rd and 4th transfers (4-staged check point)

1 – forward

2 – small facet

Prevention

Forward and back needle bearings of a secondary shaft are interchanged. That rollers were not scattered, before assembly put lubricant in bearings.


Assembly

PERFORMANCE ORDER
1. Install needle bearings on a secondary shaft.
2. Establish the conducted gear wheel of the 2nd transfer so that a conical part of a gear wheel was turned back.
3. Install the needle bearing on a secondary shaft. Establish the conducted gear wheel of the 1st transfer so that a conical part of a gear wheel was turned forward.
4. Establish a persistent washer by a lubricant flute forward. Napressuyte on the secondary basic bearing.
5. Install needle bearings. Establish the conducted gear wheel of the 3rd transfer, the blocking ring and the synchronizer 3rd and 4th of transfers.
6. Establish a lock ring and measure a gap between a lock ring and a blocking ring of the synchronizer which has to be within 0,0–0,05 m. The gap is regulated by selection of a lock ring.
7. Establish the blocking ring of the synchronizer of the 3rd and 4th transfers and the needle bearing.
8. Press the forward basic bearing of a secondary shaft so that the flute under a spring ring was turned forward. Install the back bearing of an intermediate shaft, the flute under a lock ring of the bearing has to be turned back.
9. Install needle bearings and an internal partition.
10. Establish a lock ring of the bearing of a secondary shaft.
11. Establish a lock ring of the bearing of an intermediate shaft.
12. Install the plug of an intermediate shaft, a backing gear wheel, a washer and wrap a nut. Tighten a shaft nut with m 100–120 N.' moment.
13. Establish a washer on a secondary shaft and tighten a nut with m 100–120 N.' moment.
14. Establish on a shaft an intermediate gear wheel, a lock ring, the spline conducting a gear wheel of a speedometer and the second lock ring.
15. Establish a shaft of an intermediate gear wheel assembled, insert a lock plate, tighten a bolt with m 34 N.' moment.
16. Insert a pin, establish forks of inclusion of all transfers, tighten a bolt with m 22 N.' moment.
17. Establish a rod and a fork of inclusion of a backing, a clamp ball, a spring and a persistent plate.
18. Establish a persistent plate of a gear wheel of a backing so that a flange part of a washer densely rested against a fillet on a partition. Establish an intermediate gear wheel of a backing so that the facet on teeths was turned outside.
19. Establish a gear wheel of a backing and a persistent washer.

Final assembly of the check point

PERFORMANCE ORDER
1. Establish an epiploon in a back cover.
2. Establish collected secondary, intermediate and primary shaft in a check point case. At installation of a secondary shaft it is forbidden to make big effort.
3. Establish a back cover, tighten bolts with m 42 N.' moment.
4. Install the backing signal switch, a reducer of a speedometer and a lock ring of the forward bearing of a secondary shaft.
5. Establish a spring washer, a forward epiploon and the holder tighten bolts with m 22 N.' moment.
6. Install the coupling switching off lever, a holder, the release bearing and the mechanism.