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>> 5-staged check point of the Trooper/Bighorn cars of early release, 4х4

6.1.5. 5-staged check point of the Trooper/Bighorn cars of early release, 4х4

GENERAL INFORMATION

Details 5-staged check point of the all-wheel drive Trooper/Bighorn cars of early release

1 – backing signal switch
2 – side case of the transfer case
3 – release bearing and holder
4 – coupling switching off lever
5 – holder of a forward epiploon
6 – spring washer
7 – lock ring
8 – speedometer reducer
9 – check point case
10 – back section of a case of the check point
11 – secondary shaft, intermediate shaft of the block of gear wheels of back and 5th transfers

Details 5-staged check point of the Trooper/Bighorn cars of early release

1 – cover of clamps
2 – spring
3 – ball
4 – rod of inclusion of the 5th transfer
5 – fork of inclusion of the 5th transfer
6 – rod of inclusion of the 1st and 2nd transfers
7 – rod of inclusion of the 3rd and 4th transfer
8 – fork of inclusion of the 3rd and 4th transfer
9 – fork of inclusion of the 1st and 2nd transfers
10 – pin and cap
11 – nut
12 – nave
13 – gear wheel
14 – holder of the needle bearing
15 – gear wheel plug
16 – lock ring
17 – lock ring of transitional section of a case
18 – average bearing of a secondary shaft
19 – oil pipeline bolt
20 – oil pipeline
21 – transitional section of a case
22 – back bearing of a secondary shaft
23 – lock ring of the bearing
24 – persistent ring
25 – the fixing ring
26 – persistent ring of the 5th transfer
27 – persistent washer of the 5th transfer
28 – lock-nut of an intermediate shaft of the 5th transfer
29 – washer
30 – bearing
31 – the conducted gear wheel of the reverse gear
32 – the leading gear wheel of the 5th transfer with a wreath
33 – needle bearing
34 – the blocking synchronizer ring
35 – nut of a secondary shaft
36 – washer
37 – synchronizer of back and 5th transfer
38 – the conducted gear wheel of the 5th transfer
39 – needle bearing

41 – persistent washer of an intermediate gear wheel of a backing
42 – intermediate gear wheel of a backing
43 – washer
44 – partition
45 – lock ring of the leading shaft
46 – a gear wheel of direct (4th) transfer with a wreath
47 – bearing
48 – needle bearing
49 – the blocking ring of the synchronizer of the 3rd and 4th transfer
50 – lock ring of a secondary shaft
51 – synchronizer 3rd and 4th of transfers
53 – the conducted gear wheel of the 3rd transfer with a wreath
54 – needle bearing
55 – block of gear wheels of the 1st and 2nd transfers
56 – persistent washer
57 – bearing of a secondary shaft
58 – bearing plug
59 – persistent washer
60 – the conducted gear wheel of the 1st transfer with a wreath
61 – bearing
62 – bearing plug
63 – the blocking ring of the synchronizer 1 and 2nd of transfers
64 – synchronizer 1 and 2nd of transfers
65 – the blocking ring of the synchronizer 1 and 2nd of transfers
66 – the conducted gear wheel of the 2nd transfer with a wreath
67 – needle bearing
68 – intermediate gear wheel of a backing
69 – bearing of an intermediate shaft
70 – intermediate shaft
71 – lock ring
72 – bearing of an intermediate shaft of the check point
73 – adjusting washer
74 – maple spring
75 – shaft of an intermediate gear wheel


Preliminary remarks

Before dismantling absolutely wash out 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 which is dissolved in gearbox oil during the operation of the mechanism of the check point. Use of jellied lubricant for bearings of naves is not allowed. 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. When using old spring rings unclench internal lock rings, and draw in external lock rings. Before assembly dip all details into gearbox oil.

Dismantling

PERFORMANCE ORDER
1. Remove the backing signal switch, a side case of the transfer case, the release bearing and a holder.
2. Remove the coupling switching off lever, forward section of a case, a spring washer and a lock ring of the forward bearing of a secondary shaft.
3. Remove a speedometer reducer, get a lock plate and a remote washer from an intermediate shaft of the 5th transfer.
4. Turn off bolts of a cover of a case of the transfer case and get a secondary shaft, an intermediate shaft of the block of gear wheels of back and 5th transfer and a main shaft from a check point case. Shaft and a partition will be in a case of the transfer case.
Secondary shaft, intermediate shaft of the block of gear wheels of back and 5th transfer and main shaft
5. Uncover clamps, get springs and balls by means of the magnetized wire.
6. Record rods a bar, having rested against a rod end face to avoid breakages. Get crackers from rods of all transfers. Remove rods and forks of gear shifting.
7. Turn out caps and get a pin.
8. Turn off a nut of a nave of a tail part of a secondary shaft, remove a nave, a gear wheel, the needle bearing, a holder and a lock ring.
9. Get a lock ring of the bearing of a secondary shaft of the check point, remove the bearing, turn out a bolt of an oil pipeline and remove an oil pipeline.
10. Remove intermediate section of a case from shaft.
11. Remove the first lock ring, a persistent ring and the second lock ring, remove a lock ring of a gear wheel of the 5th transfer and a washer.
12. Turn off a nut of an intermediate shaft of the 5th transfer, remove a washer and the bearing of a shaft. Remove an intermediate gear wheel of the 5th transfer (to remove the bearing and a gear wheel a trekhlapny stripper).
13. Remove the conducted gear wheel of the 5th transfer with a cone, needle bearings and the blocking synchronizer ring.
14. Dress couplings of synchronizers 1/2 and 3/4 of transfers on the conducted gear wheels of the 1st and 3rd transfers respectively, turn off a nut of a secondary shaft and remove a washer.
15. Remove the synchronizer of back and 5th transfers assembled, remove a gear wheel of a backing and the needle bearing.
16. Turn off a backing gear wheel shaft nut, remove a gear wheel and persistent washers.
17. Remove a partition from shaft.
18. Get a lock ring from a main shaft of the check point and remove a gear wheel. Vypressuyte bearing.
19. Remove the needle bearing and the blocking ring of the 3rd and 4th transfers from a main shaft.
20. Get a lock ring from a secondary shaft, remove details of the synchronizer of the 3rd and 4th transfers and the blocking ring of the 3rd transfer.
21. Remove the conducted gear wheel of the 3rd transfer assembled with a cone and needle bearings.
22. Gear wheels and bearings of a secondary shaft should be removed by means of a press and a stripper.
23. Vypressuyte bearing of a secondary shaft. Get the bearing plug, a persistent washer, remove a gear wheel of the 1st transfer with a cone, needle bearings, the second plug, the first blocking ring of the synchronizer 1 and 2nd of transfers, details of the synchronizer 1 and 2nd of transfers, the second blocking ring and the conducted gear wheel of the 2nd transfer.
24. Get needle bearings from a gear wheel of the 2nd transfer.
25. Press a gear wheel and the bearing from an intermediate shaft. Remove lock rings of forward and back bearings of a shaft, remove a maple spring and turn out a shaft.

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 – 6,5–7,2 mm, a fork of turning on of the transfer case – 6,0–6,8 mm, back and 5th transfers of 6,3-6,9 mm.
2. Measure length of springs of clamps. Length of springs of a clamp of the 1st, 2nd, 3rd and 4th and back transfers in a free state – 25,0–27,7 mm, the transfer case of 41,0-43,0 mm.
3. Check elasticity of springs which has to be for clamps of the 1st, 2nd, 3rd and 4th and back transfers of 6,3-6,7 kgfs and for the transfer case of 9,0-11 kgfs.
4. Check a gap between the blocking rings and end faces of gear wreaths of gear wheels. Standard gap: for gear wheels of the 1st and 2nd transfers – 0,8–1,7 mm, for gear wheels of the 3rd and 5th transfers – 0,8–1,7 mm, the 4th transfer – 0,8–1,3 mm.
5. Check a gap between the blocking rings and crackers. The gap has to be within 3,51–4,00 mm.
6. Check a gap between a nave of the synchronizer and crackers. The gap has to be within 0,01–0,03 mm.
7. Check a beating of a secondary shaft (should not exceed 0,05 mm).
8. Measure the internal diameter of gear wheels which has to be: for 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, for an intermediate gear wheel of the transfer case – 33,0–33,1 mm and for a gear wheel of the 5th transfer – 32,03–32,10 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. By means of the arrow indicator check a side play in gearing of gear wheels. The side play measured on naves of the synchronizer has to be within 0,0–0,20 mm, a side play of gear wheels of a backing – 0,062–0,200 mm.
11. Check a side play in ball bearings which should not exceed 0,2 mm.
12. Replace details which do not satisfy to the specified norms.

Assembly

PERFORMANCE ORDER
1. Install needle bearings of the 2nd transfer on a secondary shaft. Establish the conducted gear wheel of the 2nd transfer so that a conical part of a gear wheel was turned back.
2. Establish the first blocking ring and the synchronizer 1 and 2nd of transfer assembled. Parallel oil flutes on a nave of the synchronizer and a big facet on the coupling of the synchronizer have to be turned into one party. Make sure that crackers came into flutes on the blocking ring. Check freedom of longitudinal movement of the coupling on a nave. Establish the second blocking ring of the synchronizer 1 and 2nd of transfer.
3. Napressuyte on a shaft a holder of the needle bearing, using a special mandrel.
4. Install needle bearings, the conducted gear wheel of the 1st transfer with details of the synchronizer and a persistent washer so that the lubricant flute of a persistent washer was turned forward.
5. Napressuyte on a secondary shaft the radial bearing. Establish a persistent washer of the conducted backing gear wheel so that the lubricant flute of a persistent washer was turned back.
6. Napressuyte holder of the needle bearing. Install needle bearings, the conducted gear wheel of the 3rd transfer with a cone and the blocking ring of the synchronizer of the 3rd and 4th transfers.
7. Establish details of the synchronizer of the 3rd and 4th transfers so that the extended party of a nave was turned to a small facet on the synchronizer coupling. Measure a gap between shaft and a nave of the synchronizer of the 3rd and 4th transfers, establish a lock ring, having picked up it for thickness.
8. Establish the second blocking ring of the synchronizer of the 3rd and 4th transfers, a napressuyta needle bearings and the bearing of a main shaft of the check point. Establish a lock ring of the bearing.
9. Establish a main shaft of the check point.
10. Napressuyte forward and back bearings of an intermediate shaft and backing. Establish lock rings of bearings.
11. Establish an intermediate shaft of the 5th transfer, the leading gear wheel of a backing and a shaft of an intermediate gear wheel of a backing. Wrap a shaft bolt with m 22 N.' moment.
12. Establish in a partition of a case of a ring of the radial bearing of a secondary shaft and the bearing of a gear wheel of the 5th transfer. Combine a secondary shaft and an intermediate shaft of the 5th transfer with openings in a partition by means of a special mandrel.
13. Establish a persistent washer of an intermediate gear wheel of a backing, the plug, the second persistent washer, wrap a nut. Tighten a nut with m 120 N.' moment.
14. Install needle bearings in a backing gear wheel, dress a gear wheel on a secondary shaft.
15. Establish details of the synchronizer of the 5th and back transfers so that, the extended party of a nave was turned to a big facet on the synchronizer coupling.
16. Establish a washer and wrap the first nut of a secondary shaft. Tighten a nut with m 140 N.' moment.
17. Establish the blocking ring of the 5th transfer, a gear wheel of the 5th transfer with a cone, the needle bearing and a persistent washer.
18. Establish persistent and lock rings so that locks of these rings were mutually perpendicular. Establish a restrictive ring and a lock ring of the bearing of a secondary shaft.
19. Establish an intermediate gear wheel of the 5th transfer, the bearing, a flat washer and tighten the second nut of a secondary shaft with m 140 N.' moment.
20. Establish intermediate section of a case, an oil pipeline and tighten an oil pipeline bolt with m 20 N.' moment.
21. Install the central bearing of a secondary shaft and a lock ring.
22. Establish a lock ring, a holder, the needle bearing, a gear wheel and a nave of a tail part of a secondary shaft, tighten the third nut of a shaft with m 140 N.' moment.
23. Establish a pin and a cap.
24. Establish forks and rods of inclusion of 1/2 and 3/4 transfers and insert crackers with springs.
25. Establish a fork and a rod of inclusion of the 5th and back transfers.
26. Establish balls, springs and a cover of clamps of rods, tighten cover bolts with m 22 N.' moment.