Isuzu Rodeo UE. Manual - part 511

7B–76

MANUAL TRANSMISSION

f

Look for evidence of gear clash on both the
synchronizer sleeve teeth or the clutch teeth on the
speed gear.

226RS124

Finally, look at the synchronizer sleeve and speed
gear clutch tooth area for cause of “hopout”.

226RS125

Reassembly

1. Use a hydraulic press and the J–6133–01 installer to

press the counter shaft rear bearing assembly(20)
onto the counter shaft(21).  Use tool J–37357 to
support the counter shaft in the transmission
case(22).

226RS126

2. Install the counter shaft rear bearing outer race(19)

and retainer(17) without the shim.

226RS127

f

Tighten the retainer bolts, using a 13 mm socket (or
a T–40 bit) and a torque wrench.

Torque: 20 N·m (15 lb ft)

MANUAL TRANSMISSION

7B–77

f

Mount a dial indicator on the case and set it up to
measure counter shaft end play.
Move the counter shaft up and down and read the
total amount of indicator travel.

226RS128

f

Select shim which is the same thickness as the
indicator reading, or up to 0.004 inch less than the
reading.

Counter Shaft

Selective Shims

Thickness

Thickness

mm

(inches)

mm

(inches)

2.553

(0.1005)

3.239

(0.1275)

2.59

(0.102)

3.28

(0.129)

2.629

(0.1035)

3.315

(0.1305)

2.67

(0.105)

3.35

(0.132)

2.705

(0.1065)

3.391

(0.1335)

2.74

(0.108)

3.43

(0.135)

2.781

(0.1095)

3.467

(0.1365)

2.82

(0.111)

3.51

(0.138)

2.858

(0.1125)

3.543

(0.1395)

2.90

(0.114)

3.58

(0.141)

2.934

(0.1155)

3.620

(0.1425)

2.97

(0.117)

3.66

(0.144)

3.010

(0.1185)

3.696

(0.1455)

3.05

(0.120)

3.73

(0.147)

3.086

(0.1215)

3.772

(0.1485)

3.12

(0.123)

3.81

(0.150)

3.162

(0.1245)

3.848

(0.1515)

3.20

(0.126)

3.886

(0.1530)

f

Remove the counter shaft rear bearing retainer and
outer race.

3. Install the reverse idler shaft(18), gear(18), and

O–ring(18).
Use a 3/16–inch diameter pin punch and hammer to
install the reverse idler shaft roll pin(18).

226RS129

4. Install the counter shaft rear bearing outer race(19),

shim(17) and retainer(17).
Tightening the bolts.

Torque: 20 N·m (15 lb ft)

226RS130

5. Bend the lock tabs on the retainer, using a punch and

hammer.

6. Install the mainshaft assembly(16) into the case.
7. Install the mainshaft rear bearing outer race(15) into

the rear of the case.

8. Install 4th speed blocking ring(14) onto the front of the

mainshaft.
Install the mainshaft thrust race(14), bearing(14), and
spacer(14) onto the front of the mainshaft.
Apply pertoleum jelly to the mainshaft pilot bearing
rollers(14) (there are 15 rollers) and install them into
the input shaft.

7B–78

MANUAL TRANSMISSION

9. Install the input shaft(13) onto the front of the

mainshaft.

10. Install the input bearing retainer(12) and bearing

outer race(12) without shim onto the front of the case.
Tighten the four bolts, using a 13 mm socket and a
torque wrench.

Torque: 20 N·m (15 lb ft)

220RS058

11. Install the 5th speed drive gear(10) and 5th

synchronizer blocking ring(10) on the rear of the
counter shaft.

12. Install the 5–R lever with reverse fork(9) and spring(9)

into the case.

230RS023

13. Assemble the 5th synchronizer and rail/fork and

install them as follows:

f

Guide the rail(8) through the reverse fork(9) and
into the front of the case.

226RS131

f

Push the 5th synchronizer assembly(8) onto the
splines of the counter shaft together with 5th shift
fork and rail(8).

f

Install the reverse blocking ring, reverse cone(8),
splined washer(8) and 5th synchronizer snap
ring(8).

f

Align the slot of the 5–R shift lever with the roller of
the 5th shift rail.

14. Install oiling funnel(4).
15. Coat the threads of the 5–R lever pivot bolt(7) with

sealer and install it(7) into the case.  Make sure that
the 5–R lever is properly aligned with the pivot bolt.
Tighten the pivot bolt, using T–50 bit and a torque
wrench.

Torque: 27 N·m (20 lb ft)

MANUAL TRANSMISSION

7B–79

16. Install the 5–R lever clip(6) using a pair of

needle-nose pliers.
Use a pair of needle nose pliers to attach the reverse
fork spring to its pin inside the case.
Check the operation of the 5–R shift mechanism at
this time.

230RS024

17. Install the 5th driven gear snap ring(11), using snap

ring pliers.
Install the clip(11) and speedometer drive gear(11)
onto the rear of the mainshaft, using installer
J–6133–01 and a hammer.  Be sure the speedometer
gear retaining clip is fully seated.

226RS132

18. Install the slip yoke snap ring(11) onto the end of the

mainshaft, using a pair of snap ring pliers.

19. Apply a 3 mm (1/8 in) bead of RTV sealant on the

sealing surface of the shift cover.
Make sure that the 1–2 and 3–4 synchronizer sleeves
are in Neutral position, as well as the 5–R shift lever.
Lower the cover onto the case, allowing the 1–2 and
3–4 forks to slide onto their sleeves.  Slide the shift
cover assembly(5) toward the 5–R lever side just
before the cover contacts the case.

230RS025

Install the ten cover-to-case bolts, beginning with the
two alignment–type bolts, using a 10 mm socket and
a torque wrench.

Torque: 14 N·m (10 lb ft)

20. Must align reverse cone with the tab(8) in the “Up” (12

o’clock) position.

226RS133