Isuzu N-Series. Manual - part 840

MANUAL TRANSMISSION 7B-21

6. Remove the rear oil seal using the flat-tip screw-

driver.

Installation

1. Apply engine oil 5W-30 around a new oil seal, and

then press in the oil seal to the rear cover using the
installer 5-8840-2750-0.

• Apply Besco L2 grease to the lip portion of the

oil seal.

Caution:
Be careful not to damage the oil seal lip portion.

2. Install the parking brake assembly.

• Refer to PARKING BRAKE ASSEMBLY.

3. Install the coupling driver.

a. Apply engine oil 5W-30 to the O-ring, and then

install the coupling driver and the O-ring.

b. Use a new lock nut and apply engine oil 5W-30

on its seat, and then fix the lock nut using the
flange holder 5-8840-2043-0.

Tighten:
Lock nut to 289 N

⋅m (29.5 kg⋅m / 213 lb⋅ft)

• After fixing it to the specified torque, align the lip

part of the nut to the V-groove of the shaft edge.
Securely caulk the two parts of the nut lip using
a chisel whose tip form is approx. 1 mm (0.04
in) radius by 60

°, to make a length (B) of 5 mm

(0.2 in) or more, and a clearance between the
bottom of the shaft and the nut lip (A) of 1.5 mm
(0.06 in) or less.

Caution:
If any crack is found on the caulking portions of the nut
after the check, replace the lock nut and caulk it again.

N7A1076E

N7A0294E

MIN
5.0mm

MIN
5.0mm

MAX
2.5mm

MAX
2.5mm

A

B

N7A0297E

7B-22 MANUAL TRANSMISSION

4. Install the parking brake drum.

• Refer to PARKING BRAKE ASSEMBLY.

5. Install the parking brake cable.

• Refer to PARKING BRAKE CABLE.

6. Install the rear propeller shaft assembly.

• Refer to REAR PROPELLER SHAFT ASSEM-

BLY.

Fixing Torque

Special Tools

Transmission Assembly

Removal

Preparation: Jack up the vehicle, and support it with rigid
racks.

1. Remove the rear propeller shaft assembly.

Caution:
Put an alignment mark on the drum and the flange yoke.
Put them aside and hang them up using a wire or some-
thing to prevent them from interrupting the work.

N7A0301E

Illustration

Tool Number / 

Description / Remarks

5-8840-2043-0 / Flange 

Holder

5-8840-2750-0 / Oil Seal 

Installer

5884020430

5884027500

MANUAL TRANSMISSION 7B-23

2. Remove the transmission side cover.

3. Remove the connection of the vehicle speed sen-

sor connector.

4. Remove the connection of the neutral switch con-

nector.

5. Remove the connection of the reverse switch con-

nector.

6. Remove the connector from the harness bracket

taking care not to damage the clip portion.

7. Disconnect the parking cable.

• Remove the cable bracket and move the cover,

and then disconnect the cable by loosening the
longer nut located to the vehicle front side.

8. Remove the shift cable split pin and disconnect the

shift cable.

9. Remove the select cable split pin and disconnect

the select cable.

10. Remove the clutch slave cylinder assembly.

• Remove the return spring and the securing

bolt, and then hang them up using a wire or
something to prevent them from interrupting
the work.

N7A0302E

N7A0303E

Legend

1. Select cable
2. Shift cable

N7A0304E

N7A0305E

7B-24 MANUAL TRANSMISSION

11. Remove the starter ground cable.
12. Remove the starter motor assembly.

• Hang them up using a wire or something to pre-

vent them from interrupting the work.

13. Remove the nut securing the transmission and the

frame (crossmember).

• Support the engine using a garage jack or a

wire, and then set the transmission jack under
the transmission and secure it with a chain not
to fall down.

• For the vehicles with a double wishbone type

suspension, remove the mounting bracket bolt
on the transmission side, if necessary, and re-
move the mounting bracket.

14. Remove the transmission assembly.

• Remove the bolt securing the clutch housing,

and then remove the transmission assembly by
operating the transmission jack.

15. Remove the mounting bracket assembly bolt, and

then remove the bracket.

Installation

1. Install the mounting bracket assembly.

Tighten:
Mounting bracket to 97 N

⋅m (9.9 kg⋅m / 72 lb⋅ft)

2. Install the transmission assembly.

• Fix and secure the transmission in the same

way of removal.

Tighten:
Transmission assembly to 46 N

⋅m (4.7 kg⋅m / 34 lb⋅ft)

N7A0306E

N7A0307E