Isuzu Rodeo UE. Manual - part 510

7B–72

MANUAL TRANSMISSION

3. Look at surfaces on the above parts which support

bearings and shafts.  Replace parts which have
excessive wear in these areas.  Do not replace gears
if phosphate coatings are worn.

220RS056

4. Examine the bearing surfaces of the following parts:

f

Input shaft

f

Mainshaft and its gears

f

Counter shaft and the fifth drive gear.

226RS168

f

Reverse idler shaft and its gear.

226RS113

Replace parts which show signs of excessive wear.
Do not file surfaces which have been hardened and
precision ground.

5. Inspect shift mechanism parts as follows:

f

Look for wear on the shift shaft.

f

Look at the detent/guide plate and offset lever for
worn edges or grooves where the detent ball and
lug travel.

230RS020

MANUAL TRANSMISSION

7B–73

f

Look for worn edges on these parts:

– Selector arm
– Interlock plate
– Selector plates for the 1–2 and 3–4 shift forks

230RS021

– 5–R shift lever and the rollers on the reverse fork

and the 5th shift rail/fork.

230RS022

f

Look for worn mating surfaces on the following
parts:

– 1–2 shift fork, pads and synchronizer sleeve

226RS114

– 3–4 shift fork, pads and synchronizer sleeve
– 5th shift rail/fork, pads and synchronizer sleeve
– Reverse fork and the mating sleeve surface of the

reverse idler gear.

6. Inspect the following bearings for excessive wear:

f

Crankshaft pilot bushing for the front of the input
shaft

f

Clutch release bearing

f

Input shaft bearing

f

Mainshaft pilot bearing rollers

f

Mainshaft thrust bearing and its mating surfaces

226RS115

7B–74

MANUAL TRANSMISSION

f

Speed gear roller bearing on the mainshaft

f

Mainshaft rear bearing

f

Counter shaft front and rear bearings.

226RS116

Replace any bearing and its races that show
roughness.

7. Inspect the gear tooth surfaces on all the gear sets.

Replace all mating gears in a set if any one has
excessive wear on the meshing surfaces of its teeth.
Look for fractures, pitting, scoring and spalling.

226RS117

226RS118

8. Disassemble the three synchronizer assemblies:

f

The 1–2, which has three-piece assemblies.

226RS119

MANUAL TRANSMISSION

7B–75

f

The 3–4, which has sintered metal blocking rings.

226RS120

f

The 5–R, which uses single-piece brass blocking
rings.

226RS121

f

Examine the fit between the hub and sleeve of each
synchronizer.
Besides binding shift linkage, an excessively tight
or loose hub-to-sleeve fit will cause what is known
as a “hard shift”.

226RS122

f

Measure the clearance between the blocking ring
and the speed gear.
Excessive wear on either the blocking ring or the
speed gear cone surface will cause “shift blockout”
or “gear clash”.

Blocking Ring to Gear Clearance

 

Standard

1–2 gear

0.87 – 1.4 mm (0.032 – 0.056 in)

3–4 gear

0.88 – 1.5 mm (0.035 – 0.059 in)

226RS123