Isuzu Rodeo UE. Manual - part 499

7B–28

MANUAL TRANSMISSION

8. Install top gear bearing snap ring(6) and counter front

bearing snap ring(5).

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Use a pair of snap ring pliers to install the snap rings
to the mainshaft and countershaft.

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The snap rings must be fully inserted into the
bearing snap ring groove.

9. Install front cover (with oil seal) (4).

Front Cover Oil Seal Replacement

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Remove the oil seal from the front cover.

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Apply engine oil to a new oil seal outer
circumference.

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Apply recommended grease to the oil seal lip.

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Use the oil seal installer J–26540 to install the oil
seal to the front cover.

220RS008

10. Install a new packing and front cover(4) to the

transmission case.

NOTE: Take care not to damage the oil seal.

Notes When Tightening the Bolt:

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After cleaning the bolt hole, dry it thoroughly with air.

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After cleaning the screw face of a removed bolt or new
one, dry it thoroughly.  Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six new front cover bolts to the specified
torque.

Torque: 25 N·m (18 lb ft)

11. Install the fulcrum bridge(3) to the transmission case.

Tighten three fulcrum bridge bolts to the specified
torque.

Torque: 38 N·m (28 lb ft)

220RS009

12. Apply grease to the pin hole inner circumferences and

thrust surfaces.
Attach the shift fork(2) to the fulcrum bridge(3) by
inserting the shift fork pin from the bottom side of the
fulcrum bridge.
Install the washer and snap pin.

201RS018

MANUAL TRANSMISSION

7B–29

13. Apply grease to the areas as shown in the figure.

201RW017

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Install the release bearing(1) to the shift fork(2) in
the proper direction.

NOTE: Ensure release bearing is properly positioned
during installation, as shown in the figure.

201RS019

7B–30

MANUAL TRANSMISSION

Transmission Case and Transfer Case

Major Component (MUA, 4X4)

220RW041

Legend

(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Ring
(7) Speedometer Sensor and Speedometer Driven

Gear

(8) Front Companion Flange
(9) Rear Companion Flange

(10) Gear Control Box Assembly

(11) 2WD–4WD Actuator Assembly

(12) Transfer Rear Case Assembly
(13) Detent, Shift Arm, and Interlock Pin
(14) Bearing Snap Ring

(15) Ball Bearing
(16) Lock Nut
(17) High-Low Clutch Hub and Sleeve
(18) Transfer Input Gear
(19) Needle Bearing
(20) Bearing Collar
(21) Ball
(22) Plate
(23) Bearing Snap Ring
(24) Front Output Gear Assembly
(25) Bearing Snap Ring
(26) Counter Gear Assembly
(27) 1–2 and 3–4 Indicator Switch, Pin, and Ball
(28) Transfer Case Assembly
(29) Intermediate Plate with Gear Assembly
(30) Transmission Case

MANUAL TRANSMISSION

7B–31

Disassembly

1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case

and transfer case and drain the lubricant.

3. Remove the clutch release bearing(1) from the

transmission case.

201RS020

4. Remove the snap pin.

Remove the shift fork pin and shift fork(2) from the
fulcrum bridge(3).

201RS021

5. Remove the fulcrum bridge bolts.

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Remove the fulcrum bridge(3) from the
transmission case.

Remove the front cover(4) and gasket from the
transmission case.

201RS022

6. Remove counter front bearing snap ring(5) and top

gear bearing snap ring(6).
Use a pair of snap ring pliers to remove the snap ring.

226RS001