Isuzu N-Series. Manual - part 849

MANUAL TRANSMISSION 7B-57

20. Using the snap ring pliers, install the snap ring and

the 6th clutch hub.

• Select the thickest snap ring of the available

three.

Caution:
When the snap ring is deformed or damaged on instal-
lation, replace it with a new one, and make sure it is
completely installed.

21. Apply engine oil 5W-30 to the shift rod hole of the

transmission case, install the 6th shift arm (3) and
6th shift rod (4), and then press in the spring pin (2)
aligning its hole.

22. Install the 6th relay lever (1).

Tighten:
6th relay lever (1) to 44 N

⋅m (4.5 kg⋅m / 32 lb⋅ft)

23. Install the needle bearing; main end.

• Apply Besco L2 grease inside the needle bear-

ing, and apply engine oil 5W-30 to the bearing
connecting bore of the rear cover.

• Press in the needle bearing to the rear cover

from outside by turning the bearing stamped
surface out and using the installer 5-8840-
2752-0 and the grip 5-8840-0007-0.

24. When replacing the rear cover oil seal with a new

one after checking for wear and damage or when
replacing the needle bearing, apply engine oil 5W-

Thickness, mm (in)

Identification Color

1.7 (0.066)

White

1.8 (0.070)

No color

1.9 (0.074)

Blue

N7A1176E

N7A1140E

N7A1178E

7B-58 MANUAL TRANSMISSION

30 around the 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.

25. Apply ThreeBond 1215 to the mating surface of the

transmission case rear cover, and then install the
rear cover.

• Wipe off moisture and lubricant from the con-

necting surface. And then apply the bond con-
tinuously with a diameter of 2 mm (0.079 in).

Tighten:
Rear cover to 46 N

⋅m (4.7 kg⋅m / 34 lb⋅ft)

Caution:
Since the two bolts with arrow marks are installed with
LOCTITE sealing agent, clean up the sealing agent re-
maining on the screw thread of the transmission case,
and then use new bolts with LOCTITE sealing agent.

26. Apply ThreeBond 1215 to the mating surface of the

transmission case reverse idle cover, and then in-
stall the reverse idle cover.

• Wipe off moisture and lubricant from the mating

surface. And then apply the bond continuously
with a diameter of 2 mm (0.079 in) or more.

N7A1076E

N7A1180E

N7A1181E

MANUAL TRANSMISSION 7B-59

Tighten:
Reverse idle cover to 20 N

⋅m (2.0 kg⋅m / 15 lb⋅ft)

27. Apply ThreeBond 1215 to the mating surface of the

transmission case PTO cover, and then install the
PTO cover.

• Wipe off moisture and lubricant from the con-

necting surface before applying it as a more
than 2 mm (0.079 in) diameter solid line.

Tighten:
PTO cover to 37 N

⋅m (3.8 kg⋅m / 27 lb⋅ft)

Caution:
Since the bolt is installed with LOCTITE sealing agent,
clean up the sealing agent remaining on the screw
thread of the transmission case, and then use a new bolt
with LOCTITE sealing agent.

28. Shift the position to the neutral, apply ThreeBond

1215 to the mating surface of the transmission
case control box, and then install the interlock plate
(8) and the control box (1).

Tighten:
Control box (1) to 27 N

⋅m (2.8 kg⋅m / 20 lb⋅ft)

• Wipe off moisture and lubricant from the mating

surface. And then apply the bond continuously
with a diameter of 2 mm (0.079 in) or more.

Caution:
Since the bolt is installed with LOCTITE sealing agent,
clean up the sealing agent remaining on the screw
thread of the transmission case, and then use a new bolt
with LOCTITE sealing agent.

29. Install the detent assembly (7) (6) (5) (4) after

cleaning up the sealing on the thread and applying
the LOCTITE 242.

Tighten:
Detent assembly (7) (6) (5) (4) to 27 N

⋅m (2.8 kg⋅m / 20

lb

⋅ft)

30. Apply LOCTITE 242 to the reverse switch thread

portion, and then install the reverse switch (3).

Tighten:
Reverse switch (3) to 39 N

⋅m (4.0 kg⋅m / 29 lb⋅ft)

31. Apply engine oil 5W-30 to the speedometer driven

gear and the O-ring, and then install the speedom-
eter driven gear (2).

Tighten:
Speedometer driven gear (2) to 20 N

⋅m (2.0 kg⋅m / 15

lb

⋅ft)

N7A1121E

N7A1122E

N7A1124E

7B-60 MANUAL TRANSMISSION

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

stall the drain plug and the O-ring.

Tighten:
Drain plug to 39 N

⋅m (4.0 kg⋅m / 29 lb⋅ft)

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

stall the filler plug and the O-ring.

Tighten:
Filler plug to 39 N

⋅m (4.0 kg⋅m / 29 lb⋅ft)

34. Install the parking brake assembly.

• Refer to PARKING BRAKE ASSEMBLY.

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

stall the coupling driver and the O-ring.

36. Use a new lock nut, apply engine oil 5W-30 to the

seat, and then fix the lock nut using the flange hold-
er 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 2.5 mm
(0.06 in) or less.

37. Install the parking brake drum and adjust hole cov-

er fixing bolt.

• Refer to PARKING BRAKE ASSEMBLY.

N7A0347E

N7A0294E

MIN
5.0mm

MIN
5.0mm

MAX
2.5mm

MAX
2.5mm

A

B

N7A0297E