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 cars of late release, 4х4

6.1.6. 5-staged check point of cars of late release, 4х4

GENERAL INFORMATION

AMIGO/MU/JAZZ, RODEO/PASSPORT, TROOPER/BIGHORN

Details 5-staged check point of all-wheel drive cars of late release

1 – speedometer reducer
2 – flange of the leading shaft
3 – holder of a forward epiploon
4 – lock ring of an intermediate shaft of the 5th transfer
5 – lock ring of the bearing
6 – cover of a distributing column
7 – case of the check point and detail of a case of the transfer case

Details of the internal device 5-staged check point of the all-wheel drive cars Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn of late release

1 – clamps of rods
2 – rod, fork and crackers
3 – block of gear wheels of the 5th and back transfers
4 – intermediate shaft
5 – primary and secondary shaft with the block of gear wheels

Partition of a case and mechanism of gear shifting

1 – clamp cover
2 – clamp spring
3 – ball
4 – spring
5 – rod of inclusion of the 5th transfer and backing
6 – fork of inclusion of the 5th transfer and backing
7 – rod of inclusion of the 1st and 2nd transfers
8 – rod of inclusion of the 3rd and 4th transfers
9 – fork of inclusion of the 3rd and 4th transfers
10 – inclusion fork 1y-y and 2nd transfers
11 – pin
12 – case partition

Preliminary remarks

(see subsection 6.1.5).

Dismantling

PERFORMANCE ORDER
1st stage
1. Fix the check point at the stand or a workbench.
2. Merge oil.
3. Remove a reducer of a speedometer and a flange of the leading shaft.
4. Remove a forward epiploon with the holder, a lock ring of an intermediate shaft of the 5th transfer and a lock ring of a main shaft.
5. Turn off bolts of fastening of the transfer case and remove a box.
2nd stage: Partition and forks of gear shifting
6. Uncover clamps, get springs and balls by means of the magnetized wire.
7. Get the forelock, remove a spring, a rod and a fork of inclusion of the 5th transfer and a backing and blocking of inclusion of a backing.
8. Remove rods and forks of inclusion of 1/2 and 3/4 transfers.
Prevention

To take the blocking crackers before removal of rods and forks of gear shifting, record the corresponding rod a bar.


9. Get the blocking crackers from a rod of inclusion of 3/4 transfers.

Assembly

PERFORMANCE ORDER
1. Establish forks of 1/2 and 3/4 transfers, a rod of inclusion of 3/4 transfers, insert pins and establish a rod of 1/2 transfers, a zashplintuyta.
2. Establish a fork of inclusion of the 5th transfer and a backing, blocking of inclusion of a backing, a rod of a fork and a spring.
3. Establish a cover of clamps, springs and balls. Tighten cover bolts with m 15 N.' moment.

BLOCK OF GEAR WHEELS OF THE 5TH TRANSFER AND BACKING

Block of gear wheels of the 5th transfer and backing (Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn)


1 – holder of epiploons
2 – bearing
3 – restrictive ring
4 – persistent plate
5 – persistent washer and ball of a clamp
6 – lock ring of an intermediate gear wheel of a backing
7 – lock ring of the bearing
8 – bearing
9 – leading gear wheel of the 5th transfer
10 – shaft of an intermediate gear wheel
11 – intermediate gear wheel of a backing
12 – persistent washer
13 – shaft pin
14 – leading gear wheel of a backing
15 – the conducted gear wheel of the 5th transfer
16 – the blocking synchronizer ring
17 – needle bearing
18 – synchronizer nave nut
19 – synchronizer of the 5th transfer and backing
20 – the blocking ring of the synchronizer of the reverse gear
21 – the conducted backing gear wheel
22 – needle bearing
23 – plate of bearings
24 – lock ring of the bearing
25 – partition

Dismantling

Synchronizer of the 5th transfer and backing

1 – nave

2 – small flute

3 – crackers

4 – spring rings

5 – coupling


Installation of a nave of the leading gear wheel of a backing


PERFORMANCE ORDER
1. Remove a holder of an epiploon and the bearing of an intermediate shaft.
2. Remove a cover, a washer and a ball of a clamp.
3. Remove lock rings and press the bearing and the conducted gear wheel of the 5th transfer from an intermediate shaft.
4. Remove a shaft of an intermediate gear wheel of a backing, a gear wheel, a persistent washer and a shaft.
5. Remove the leading gear wheel of a backing, the blocking ring of the 5th transfer and needle bearings.
6. Block synchronizers 3/4 and 1/2 of transfers, having dressed couplings respectively on wreaths of the 3rd transfer and 1 transfers, and turn off a nave nut.
7. Remove details of the synchronizer of the 5th transfer and a backing, working with two mounts as levers.
8. Get the blocking ring of the synchronizer of the reverse gear, the leading gear wheel of a backing and the needle bearing.
9. Turn off bolts with secret six-sided heads and remove a persistent plate of the bearing.
10. Remove a lock ring of the bearing and a partition.

Assembly

PERFORMANCE ORDER
1. Establish a case partition.
2. Tighten bearing plate bolts with m 15 N.' moment, previously having greased them with the structure fixing from an otvorachivaniye.
3. Put on a secondary shaft of a gear wheel, the synchronizer 5th and back transfers, tighten a nut with 128 N.' moment of m of Raskernite a nut.
4. Install the needle bearing, the blocking ring of the synchronizer of the 5th transfer and the leading gear wheel of the 5th transfer.
5. Establish the leading gear wheel of a backing so that the acting part of a gear wheel was turned towards a partition. Collect a shaft of an intermediate gear wheel of a backing with gear wheels and washers and the plastic hammer press in a partition.
6. Install the bearing and an adjusting ring which compensates a gap to 0,15 mm.
7. Establish a washer, a clamp ball, a plate, a restrictive ring, the bearing and a holder of an epiploon.

PRIMARY, SECONDARY AND INTERMEDIATE SHAFT

Primary, secondary, intermediate shaft 5-staged check point (Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn)

1 – lock ring of a main shaft
2 – main shaft
3 – ball bearing
4 – needle bearings
5 – the blocking ring of the synchronizer of the 4th transfer
6 – lock ring of a secondary shaft
7 – synchronizer 3/4 of transfers
8 – the blocking ring of the synchronizer of the 3rd transfer
9 – leading gear wheel of the 3rd transfer
10 – needle bearings
11 – holder of the needle bearing
12 – bearing of a secondary shaft
13 – the persistent bearing of the conducted gear wheel of the 1st transfer

14 – the conducted gear wheel of the 1st transfer
15 – the blocking ring of the synchronizer of the 1st transfer
16 – needle bearings
17 – lock ring of a nave of the synchronizer
18 – synchronizer 1/2 of transfers
19 – the blocking ring of the synchronizer of the 2nd transfer
20 – the conducted gear wheel of the 2nd transfer
21 – needle bearings
22 – secondary shaft
23 – lock ring
24 – bearings of an intermediate shaft
25 – bearings of an intermediate shaft
26 – intermediate shaft


Dismantling

PERFORMANCE ORDER
1. Remove a lock ring, a main shaft, the needle bearing, a vypressuyta the bearing of a main shaft.
2. Get the blocking ring, a lock ring of a secondary shaft and remove the synchronizer 3/4 of transfers.
3. Get the second blocking ring, the leading gear wheel of the 3rd transfer, the needle bearing, a vypressuyta a holder of the needle bearing.
4. Vypressuyte the bearing of a secondary shaft, remove the persistent bearing and the conducted gear wheel of the 1st transfer.
5. Remove the blocking ring of the synchronizer of the 1st transfer, needle bearings and a lock ring.
6. Remove the synchronizer 1/2 of transfers assembled, the blocking ring of the synchronizer of the 2nd transfer, the conducted gear wheel of the 2nd transfer and needle bearings.
7. Remove a lock ring from an intermediate shaft and press both bearings.

Assembly

PERFORMANCE ORDER
1. Dress the needle bearing and the conducted gear wheel of the 2nd transfer on a secondary shaft. The auxiliary gear wreath of a gear wheel has to be turned back.
2. Establish the blocking ring of the synchronizer of the 2nd transfer and the synchronizer 1/2 of transfers assembled. A small flute on the coupling and a flat surface of a nave have to be turned into one party. Check freedom of longitudinal movement of the coupling on a nave.
3. Establish the adjusting ring, the needle bearing blocking a synchronizer ring, the conducted gear wheel of the 1st transfer and the persistent bearing which has to be turned by a front part forward.
4. Napressuyte bearing of a secondary shaft and holder of the needle bearing.
5. Install the needle bearing of a gear wheel of the 3rd transfer, the blocking synchronizer ring, the conducted gear wheel of the 3rd transfer and the synchronizer 3/4 of transfers assembled. The auxiliary gear wreath of the conducted gear wheel of the 3rd transfer has to be turned forward. Orient a nave so that the acting part of a nave was turned towards a ring pro-point on the external surface of the coupling. Check freedom of longitudinal movement of the coupling on a nave.
6. Establish the adjusting ring, the needle bearing blocking a ring and a main shaft.
7. Both bearings also establish to Napressuyta a lock ring on an intermediate shaft.
8. Bearings also establish to Napressuyta on an intermediate shaft a lock ring.

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 – 9,0–9,8 mm, the 3rd and 4th transfers – 9,0–9,9 mm, back and 5th transfers of 9,0-9,9 mm.
2. Measure length of springs of clamps which has to be 26,2–26,8 mm for all transfers. For a spring of a clamp of turning on of the transfer case – 15,3–15,9 mm.
3. Check elasticity of springs which for clamps of all transfers has to be 8,9–9,9 kgfs and for the mechanism of turning on of the transfer case – 6,6–7,6 kgfs.
4. Check a gap between the blocking rings and end faces of gear wreaths of gear wheels. A standard gap – 0,8–1,5 mm.
5. Check a gap between the blocking rings and crackers. The gap has to be within 3,51–4,00 mm for the 3rd and 4th transfers, for the 5th transfer – 4,34–5,00 mm, for the others – 3,59–4,10 mm.
6. Check a gap between a nave of the synchronizer and crackers which has to be within 0,01–0,03 mm.
7. Check a beating of a secondary shaft which should not exceed 0,05 mm.
8. Measure the internal diameter of the conducted gear wheels which has to be: for gear wheels of the 1st and 3rd transfers of 45,0-45,1 mm, for a gear wheel of the 2nd transfer – 52,0–52,1 mm, for a gear wheel of the transfer case and a backing – 48,0–48,1 mm and for a gear wheel of the 5th transfer – 32,0–32,10 mm.
9. Check a gap between the plug and shaft of an intermediate gear wheel of a backing (norm of 0,041-0,150 mm).
10. Check a side play in gearing of gear wheels. The side play measured on naves of synchronizers has to be within 0,0–0,20 mm, a side play of gear wheels of a backing – 0,0–0,3 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 of the check point


PERFORMANCE ORDER
1. Apply sealant on the demountable plane of a case of the transfer case.
2. Transfer the synchronizer of a demultiplicator of the transfer case to situation "4H". Turn the ram of the transfer case so that the ledge on the ram came into a coulisse groove.
3. Establish shaft and a partition in a case of the check point and the transfer case. Selection on a head part of a rod has to be combined with deepening of the limiter in a cover of a case of the transfer case.
4. Tighten bolts of fastening of a case of the transfer case to a check point case with m 37 N.' moment.
5. Establish lock rings of bearings of intermediate and primary shaft.
6. Apply sealant on forward section of a case and press a new epiploon. Establish section and tighten bolts with m 19 N.' moment.
7. Establish a flange of the leading shaft and a reducer of a speedometer.