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 Borg-Warner check point of the Rodeo/Passport cars

6.1.7. 5-staged Borg-Warner check point of the Rodeo/Passport cars

GENERAL INFORMATION

Details of a 5-staged box of Borg-Warner of the Rodeo/Passport cars

1 – lock ring
2 – the conducted gear wheel of the 5th transfer
3 – synchronizer coupling cracker
4 – pin
5 – secondary shaft
6 – bearing holder
7 – lock ring
8 – the roller persistent bearing with a holder
9 – bell
10 – shock-absorbing plug
11 – coulisse
12 – spring and ball of a clamp
13 – epiploon
14 – information plate
15 – transitional section of a case
16 – сапун
17 – plug and shaft of an intermediate gear wheel of a backing
18 – main shaft
19 – bearing
20 – epiploon of a cover of the bearing and washer
21 – bearing cover
22 – the directing bolt and the switch of a signal of a backing
23 – case
24 – drain stopper
25 – back bearing and expansion
26 – lever of inclusion of the 5th transfer and backing
27 – fork and rod of the 5th transfer and backing
28 – pin
29 – spring ring and coupling of the synchronizer of the 5th transfer
30 – holder of crackers

 

31 – the blocking ring, a nave and crackers of the synchronizer of the 5th transfer
32 – lock ring and washer
33 – forward bearing and persistent washer of an intermediate shaft
34 – gear wheel of an intermediate shaft
35 – needle bearing and holder
36 – the conducted gear wheel of the 5th transfer
37 – the blocking ring of the synchronizer of the 3rd and 4th transfers
38 – the conducted gear wheel of the 3rd transfer
39 – lock ring
40 – the blocking ring
41 – the directing bearing of a secondary shaft
42 – the blocking ring
43 – spring, crackers and coupling of the 3rd and 4th transfers
44 – fork of switching of the 3rd and 4th transfers
45 – the blocking coupling and a finger
46 – the gear sliding coupling of a backing and a spring ring
47 – the conducted gear wheel of the 2nd transfer
48 – cap
49 – cover
50 – sealing ring
51 – crackers
52 – fork of inclusion of the 1st and 2nd transfers
53 – rod
54 – secondary shaft
55 – the blocking ring
56 – the conducted gear wheel of the 1st transfer
57 – persistent washer, back bearing and cover


1st stage of dismantling

PERFORMANCE ORDER
1. Merge oil.
2. Beat out the pin fixing the coulisse of a control lever of the check point on a gear shifting rod.
3. Remove transitional section of a case of the check point together with the coulisse.
4. Get a spring and a ball of a clamp from the coulisse. Get the directing pin from back or transitional section.
5. Remove the back persistent bearing of a secondary shaft and a holder of the bearing.
6. Uncover a case of transmission and a fork of inclusion of transfers. Two bolts of a cover are at the same time directing pins. Before removal of bolts apply on them tags that at assembly to establish on former places.
7. Get the spring ring fixing the directing bolt of a rod of turning on of the reverse gear.
8. Turn out a lock bolt, get a rod with a fork.
9. Put a tag of mutual orientation of a cover of the forward bearing concerning a case, turn off bolts and uncover.
10. Get a holder of the forward bearing and a washer from a cover. Hook and get an epiploon.
11. Turn a main shaft and get from a case.
12. Remove persistent and roller bearings from a main shaft. Remove a holder of the bearing of a secondary shaft. If necessary weaken a shaft easy blows of the plastic hammer.
13. Raise and incline a secondary shaft, get a shaft assembled from a case.
14. Carefully press the back bearing of an intermediate shaft, previously having marked orientation of the bearing concerning a shaft.
15. Displace an intermediate shaft back and having inclined get from a case. Remove the remote plug.
16. Get a pin of a shaft of an intermediate gear wheel of a backing and remove a shaft assembled with a gear wheel.
17. Press the forward bearing from an intermediate shaft and the directing bearing from a main shaft.

18. Turn out the backing signal switch from a case.


Dismantling of a secondary shaft

PERFORMANCE ORDER
1. Remove a washer of the persistent bearing from a forward part of a shaft.
2. Put tags of mutual orientation to the coupling and a nave of the synchronizer of the 3rd and 4th transfers.
3. Remove the synchronizer 3rd and 4th of transfers assembled with the blocking ring, the coupling and a nave.
4. Get spring rings, crackers and remove the coupling from a nave.
5. Remove the conducted gear wheel of the 3rd transfer.
6. Remove a lock ring of a gear wheel of the 2nd transfer, a persistent washer and a gear wheel.
7. Press the bearing from a shaft.
8. Remove a persistent washer of a gear wheel of the 1st transfer, get a pin, remove a gear wheel and the blocking ring.
9. Put tags of mutual orientation of the coupling of the synchronizer 1 and 2nd of transfers and a secondary shaft.
10. Get spring rings and remove crackers from the gear coupling, remove the coupling from a shaft.

Assembly of a secondary shaft

PERFORMANCE ORDER
1. Grease a shaft and internal surfaces of gear wheels with gearbox oil.
2. Dress the coupling of the synchronizer 1 and 2nd of transfers on a nave, having combined the tags put when dismantling.
3. Install three crackers and two spring rings in the coupling of the 1st transfer.
Prevention

At assembly to orient crackers and springs in a former order, joints of spring rings have to be directed in different directions.


4. Establish the blocking ring and the conducted gear wheel of the 2nd transfer on a shaft.
5. Establish a persistent washer and a lock ring of a gear wheel of the 2nd transfer, the washer has to come into a flute completely.
6. Establish the blocking ring and the conducted gear wheel of the 1st transfer, then insert a gear wheel pin.
7. Napressuyte on a shaft the back bearing.
8. Establish other details on a shaft: a persistent washer of a gear wheel of the 1st transfer, the conducted gear wheel of the 3rd transfer, the synchronizer 3rd and 4th of transfers. Establish a washer of the back persistent bearing of an intermediate shaft.

Dismantling of the mechanism of management of the check point

PERFORMANCE ORDER
1. Expose crackers and a rod in neutral situation.
2. Turn a rod counterclockwise that crackers left gearing with the coupling. In this situation access to a finger opens.
3. Press a rod back against the stop of the coupling into a fork of inclusion of the 1st and 2nd transfers.
4. Beat out a finger and get a rod.
5. Remove forks, the coupling, a finger and crackers.
6. Get an epiploon and a sealing ring.
7. Get nylon inserts and crackers from forks.
Prevention

Mark a relative positioning of details that at assembly to establish on former places.



Assembly

PERFORMANCE ORDER
1. Establish nylon inserts and crackers in forks.
2. Grease caps with sealant and turn.
3. Grease rods and openings of rods with technical vaseline. Insert a rod into a cover so that the end face of a rod was aflush with edge of a cover.
4. Establish a fork of inclusion of the 1st and 2nd transfers by the acting part towards a back part of a cover. Enter a rod into a fork.
5. Establish a horseshoe blocking plate of the coupling and a fork in a cover, push a rod in a fork. The widest part of the blocking coupling has to be turned from a cover aside, and the finger of the coupling has to be turned down, towards a back part of a cover.
6. Establish a fork of inclusion of the 3rd and 4th transfers so that the part of a fork displaced from an axis was turned towards a back part of a cover. The cracker of a fork of the 3rd and 4th transfers has to be located under a cracker of a fork of the 1st and 2nd transfers.
7. Push a rod through a fork and enter into a forward opening of a cover.
8. Turn a rod so that the cracker was recorded.
9. Press a finger, having combined openings in a rod and the coupling. The finger has to be aflush with the surface of the coupling.
10. Establish a sealing ring in a rod epiploon flute, grease and establish an epiploon.

Assembly of a box

PERFORMANCE ORDER
1. Grease an external holder of the bearing of an intermediate shaft with the structure fixing from a provorachivaniye (for example Loctite 601), press the bearing so that the holder appeared aflush with a case.
2. Grease a persistent washer of an intermediate shaft with technical vaseline and establish a washer so that tooth of a washer came into deepening in a case.
3. Establish a case vertically and enter an intermediate shaft into an opening for the bearing.
4. Install the remote plug, grease with technical vaseline the back bearing. Press the bearing. The bearing end face after a press fitting has to act on 3 mm over a case surface.
5. Establish an intermediate gear wheel of a backing (a flute back), a shaft of a gear wheel and fix by a pin.
6. Establish a secondary shaft assembled.
7. Napressuyte on a main shaft the leading gear wheel. Grease with technical vaseline roller bearings and insert them into a flute on a gear wheel. Install the persistent bearing and a holder.
8. Establish the blocking ring of the synchronizer of the 4th transfer on a secondary shaft. Establish a holder of the back persistent bearing of a secondary shaft.
9. Establish in a case the leading gear wheel assembled, having entered into gearing with the blocking synchronizer ring.
10. Establish new epiploons in transitional section of a case and in a cover of the forward bearing of a main shaft.
11. Install the forward bearing. Temporarily establish a cover in a case, you do not apply sealant.
12. Install the lever of turning on of the reverse gear, wrap a lever axis (grease a carving with non-drying sealant) and establish a spring ring. Make sure that the fork came into gearing with an intermediate gear wheel of a backing.
13. Grease with technical vaseline a holder and the persistent bearing, establish these details in transitional section of a case.
14. Temporarily establish (without sealant) transitional section of a case of the check point, slightly tighten fastening bolts.
15. Check an axial side play of a secondary shaft, having installed a box vertically. To choose a side play it is necessary to create a preliminary tightness in bearings, having wrung out them on 0,025–0,130 mm. Measure an axial side play and pick up a package of adjusting washers which thickness on 0,025–0,130 mm (tightness size) is more than measured side play.
16. Install a package of washers under a cover of the forward bearing of a main shaft. Apply a RTV sealant drop on a cover. Establish a cover in a case, previously having combined tags. Tighten bolts with 18 N.' moment of m and check an axial side play of a secondary shaft. The side play has to be absent. If necessary repeat adjustment.
17. Remove transitional section Move couplings of synchronizers and a fork to neutral situation. Grease with RTV sealant a demountable surface of a cover of a case. Combine forks with couplings of synchronizers and carefully establish a cover into place. Center a cover and insert the directing pins. Tighten bolts with m 10 N.' moment.
Prevention

In the correct situation the finger connecting a rod and the coupling has to be in vertical position. Otherwise repeat actions according to item 17.


18. Grease with sealant transitional section and establish on a secondary shaft.
Prevention

The rod has to enter a case cover opening freely.


19. Establish a clamp spring to the coulisse, enclose a ball in the deepening of a cover of a clamp corresponding to neutral situation. Press a spring and displace the coulisse along a rod then establish transitional section of a case (or a tail part of a case) on a check point case. Tighten bolts with m 34 N.' moment.
20. Connect a pin the coulisse and a rod. Install the shock-absorbing plug to the coulisse. Grease a backing signal switch carving with sealant and tighten the switch with m 20 N.' moment.