Isuzu N-Series. Manual - part 804

SERVICE INFORMATION 00-1

MANUAL TRANSMISSION AND CLUTCH

MSB SERIES

SECTION 00

SERVICE INFORMATION

Contents

TROUBLESHOOTING .......................................... 00-2

Transmission ..................................................... 00-2
Clutch ................................................................ 00-3

MAIN DATA AND SPECIFICATIONS ................... 00-4
SERVICE STANDARD.......................................... 00-5

Transmission ..................................................... 00-5
Clutch ................................................................ 00-6

SERVICING .......................................................... 00-7

Transmission Oil Level Check ........................... 00-7
Transmission Oil Change .................................. 00-7
Gear Control Cable Adjustment......................... 00-7
Clutch Pedal Travel and Free Play Adjustment..... 00-8
Clutch Hydraulic Circuits Bleeding .................. 00-11

FIXING TORQUE................................................ 00-12

Transmission ................................................... 00-12
Clutch .............................................................. 00-13

SPECIAL TOOLS................................................ 00-14

Transmission ................................................... 00-14
Power Take Off................................................ 00-15
Clutch .............................................................. 00-15

00-2 SERVICE INFORMATION

TROUBLESHOOTING

Transmission

PROBLEM

POSSIBLE CAUSE

CORRECTION

Abnormal Noise

1. Flywheel pilot bearing worn.

1. Replace.

2. Bearing worn or broken (Main shaft or

counter shaft).

2. Repair or replace.

3. Anti-lash plate malfunction.

3. Repair or replace.

4. Gear tooth contact surface worn or

scuffed (Main shaft, counter shaft and/
or reverse idle gear).

4. Repair or replace.

5. Spline worn (Synchronizer clutch hub).

5. Replace.

6. Gear, clutch hub or thrust washer thrust

face seized.

6. Replace.

7. Lack of backlash between mating

gears.

7. Replace.

Hard Shifting

1. Improper church pedal free play.

1. Readjust.

2. Wrong oil in use.

2. Replace with recommended oil.

3. Gear control linkage misadjust.

3. Readjust.

4. Change lever sliding portions worn.

4. Repair or replace.

5. Shift block, shift rod and/or control box

sliding faces worn.

5. Repair or replace.

6. Shift arm and/or synchronizer sleeve

groove worn.

6. Replace.

7. Synchronizer parts worn or weakened.

7. Replace.

8. Thrust washer, collar, and/or gear

thrust faces worn (Main shaft and/or
counter shaft thrust play).

8. Replace.

Walking or Jumping out
of Gear

1. Gear control linkage misadjust.

1. Readjust.

2. Detent spring weakened or broken.

2. Replace.

3. Detent ball worn.

3. Replace.

4. Change lever sliding portions worn.

4. Repair or replace.

5. Shift block, shift rod and/or control box

sliding faces worn.

5. Repair or replace.

6. Shift arm and/or synchronizer sleeve

groove worn.

6. Replace.

7. Synchronizer parts worn or weakened.

7. Replace.

8. Thrust washer, collar, and/or gear

thrust faces worn (Main shaft and/or
counter shaft thrust play).

8. Replace.

9. Spline worn (Synchronizer hub).

9. Replace.

10. Bearings worn or broken.

10. Replace.

SERVICE INFORMATION 00-3

Clutch

PROBLEM

POSSIBLE CAUSE

CORRECTION

Dragging

1. Hydraulic line leakage.

1. Repair.

2. Air in line.

2. Bleed and check for damage.

3. Master cylinder and/or slave cylinder

piston cup worn.

3. Replace.

4. Driven plate worn or warped.

4. Replace driven plate.

5. Diaphragm spring weak or tip of finger

worn.

5. Replace pressure plate assembly.

6. Driven plate sticking on spline.

6. Clean and free spline and lubricate with

grease.

7. Release bearing worn or damaged.

7. Replace release bearing.

8. Clutch pedal excessive free play.

8. Readjust.

Slipping

1. Driven plate facing worn or oil soaked.

1. Replace driven plate and check for

leaks as needed.

2. Diaphragm spring weak.

2. Replace pressure plate assembly.

3. Pressure plate and/or flywheel warped.

3. Repair or replace.

4. Clutch pedal lack of free play.

4. Readjust.

Shudder
(Chattering)

1. Engine mounting loose or broken.

1. Tighten or replace.

2. Driven plate facing warped.

2. Replace driven plate.

3. Driven plate surface of facing hard-

ened.

3. Replace driven plate.

4. Driven plate facing oil soaked.

4. Replace driven plate and check for

leaks.

5. Driven plate damper spring weakened

or broken.

5. Replace driven plate.

6. Pressure plate and/or flywheel warped.

6. Repair or replace.

Noisy

1. Release bearing binding.

1. Clean or replace if damaged, and lubri-

cate.

2. Release bearing worn or broken.

2. Replace.

3. Release bearing insufficiently lubricate.

3. Lubricate with grease or replace.

4. Driven plate damper springs weakened

or broken.

4. Replace driven plate.

5. Pilot bearing worn or broken.

5. Replace.

6. Driven plate rivet loosen.

6. Replace driven plate.

7. Ball stud insufficiently lubricate.

7. Lubricate with grease.

8. Clutch pedal lack of free play.

8. Readjust.

9. Clutch pedal shaft insufficiently lubri-

cate.

9. Lubricate with grease.

10. Pilot bearing loose or broken.

10. Replace.

Pedal is Hard to Push

1. hydraulic line blocked or crimped.

1. Clean out or replace.

2. Clutch pedal shaft insufficiently lubri-

cate.

2. Lubricate with grease.

00-4 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS

Transmission

Power Take Off

Clutch

Type

MSB-5 5 Speed

Gear Mesh Type

1st to 5th:

Synchro-mesh

Reverse:

Constant-mesh

Control Type

Floor remote control

Gear Ratio

MSB-5S

MSB-5M

1st:

5.016

5.594

2nd:

2.672

2.814

3rd:

1.585

1.660

4th:

1.000

5th:

0.770

0.794

Reverse:

4.783

5.334

Lubricating Oil

Engine Oil SAE 5W-30

Oil Capacity

L (US

qt/Imp qt)

Approx. 2.7 (2.9/2.4)

AIlowable Maximum Torque

⋅m (kg⋅m / lb⋅ft)

147 (15/108.4) / at output shaft 1000 RPM

Gear Ratio (to Engine)

1.8214

Revolution Direction

Clockwise (viewed from rear)

Pressure Plate

NKR55

NHR55 / NKR55 / NHR69

Spring Type

Diaphragm

Outside Diameter

mm (in)

240 (9.4)

250 (9.8)

Clamping Force

N (kg/lb)

4,119 (420/926)

6,276 (640/1,411)

Spring Finger Height

mm (in)

40.7 — 42.7 (1.60 — 1.68)

39.0 — 41.0 (1.54 — 1.61)

Driven Plate

Inside

× Outside Diameter

mm (in)

240

× 160 (9.4 × 6.3)

250

× 160 (9.8 × 6.3)

Free Thickness

mm (in)

7.5 — 8.1 (0.295 — 0.319)

8.1 — 8.7 (0.319 — 0.343)

Clamping Thickness

mm (in)

7.1 — 7.7 (0.280 — 0.303)

7.7 — 8.3 (0.303 — 0.327)

Clutch Pedal

Height

mm (in)

160 — 170 (6.3 — 6.7)

Stroke

mm (in)

159 — 169 (6.3 — 6.7)

Free Play

mm (in)

15 — 25 (0.6 — 1.0)

Master Cylinder

Bore Diameter

mm (in)

φ 19.050 — 19.102 (0.7500 — 0.7520)

SIave Cylinder

Bore Diameter

mm (in)

φ 26.990 — 27.042 (1.0626 — 1.0646)

Content .. 802 803 804 805 ..