Isuzu N-Series. Manual - part 852

MANUAL TRANSMISSION 7B-69

18. Measure the clearance A between the block ring

and the clutch hub using a thickness gauge.

• If the measured value exceeds the limit, re-

place the block and clutch hub.

Assembly

• Clean up each part.

• Set the main shaft in a vise, with the long spline

part at the bottom. When setting the main shaft,
make sure not to damage the grind surface.

1. Assemble the 2nd-3rd clutch hub assembly &

sleeve following the procedure below.
a. Install the block and sleeve to the clutch hub.
b. Inside the sleeve, there are three ball grooves.

Align the phase to let the ball enter the center
of the ball grooves.

c. Insert sleeve (1) until the clutch hub (5) slightly

overlaps the block.

d. Securely insert the sleeve until the ball enters

the ball groove of the sleeve by pushing the ball
(2), block (3) and spring (4).

2. Apply engine oil 5W-30 to the needle bearing, 2nd

gear thrust surface and synchro cone taper sur-
face. And install the 2nd gear (6) and needle bear-
ing (5) to the main shaft with the dog gear turned
upward.

Clearance between Block Ring and Clutch Hub, mm
(in)

Standard

2nd / 3rd

4.30 — 4.70 (0.16929 — 0.18503)

1st / Reverse

4.30 — 4.70 (0.16929 — 0.18503)

Legend

1. Block ring
2. Clutch hub

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7B-70 MANUAL TRANSMISSION

3. Install the 2nd inside ring (4), 2nd outside ring (3)

and 2nd block ring (2) inserting the nail of the out-
side ring into the gear hole of the 2nd gear. At this
time, make sure to apply engine oil 5W-30 suffi-
ciently to the both sides of the inside ring and out-
side ring, and inside diameter surface of the block
ring.

4. Insert the 2nd-3rd clutch hub assembly & sleeve

with a press using the installer 5-8840-2345-0, set-
ting the six nails of the inside ring to enter the six
holes of the hub.

5. During installation, set the six nails of the inside

ring of the 3rd block ring (7), 3rd outside ring (6)
and 3rd inside ring (5) to enter the six hub holes re-
spectively. At this time, apply engine oil 5W-30 suf-
ficiently to the inside surface of the outside ring and
the inside diameter surface of the block ring.

6. Apply engine oil 5W-30 to the needle bearing, 3rd

gear thrust surface and synchro cone taper. Turn
the dog gear downward, and insert the 3rd gear
(4), needle bearing (3) and collar (2) with a press
using the installer 5-8840-2345-0, setting the nail
of the outer ring to enter the dog gear hole of the
3rd gear.

7. Install the snap ring (1) using snap ring pliers.

Caution:
Replace deformed or damaged snap rings with new
ones. Check that the parts are securely installed.

8. Assemble the 4th-5th clutch hub assembly &

sleeve following the procedure below.
a. Assemble securely the insert (2) to the insert

groove of the block ring.

b. Install the insert spring (3) to the insert.

Caution:

• When assembling the insert spring, equalize the

length of the both edges of the spring not to ad-
versely interfere with the inside diameter of the
hub.

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MANUAL TRANSMISSION 7B-71

• Make sure that the open part of the insert spring

assembled on the reverse side, is not aligned with
the open part of the front side.

c. Check that the clutch hub (5) and sleeve (4) are

smoothly sliding.

• The arrow (1) indicates the front side of the

transmission.

9. Apply engine oil 5W-30 sufficiently to the needle

bearing, 5th gear thrust surface and synchro cone
taper, and install the 5th gear (5) and needle bear-
ing (4) with the dog gear turned upward.

10. Apply engine oil 5W-30 to the 5th block ring (3),

and install.

11. Turning the surface with oil groove downward,

align the 4th-5th clutch hub assembly and sleeve
(2) to the groove of the 4th-5th block ring, and then
insert with a press using the installer 5-8840-2345-
0.

12. Install the snap ring (1) using snap ring pliers.

Caution:
Replace deformed or damaged snap rings with new
ones. Check that the parts are securely installed.

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7B-72 MANUAL TRANSMISSION

13. Assemble the 1st-reverse clutch hub assembly

and sleeve following the procedure below.
a. Install the block and spring to the clutch hub.
b. Inside the sleeve, there are three ball grooves.

Align the phase to let the ball enter the ball
groove.

c. Insert the sleeve (1) until the block slightly over-

laps the clutch hub (5).

d. Securely insert the sleeve until the ball enters

the ball groove of the sleeve by pushing the ball
(2), block (3) and spring (4).

14. Apply engine oil 5W-30 to the needle bearing, 1st

gear thrust surface and synchro cone taper sur-
face. And install the 1st gear (6) and needle bear-
ing (5), turning the dog gear upward.

15. Assemble the 1st inside ring (4), 1st outside ring

(3) and 1st block ring (2), inserting the nail of the
outer ring into the dog gear hole of the 1st gear. At
this time, make sure to apply engine oil 5W-30 suf-
ficiently to the both sides of the inside ring and out-
side ring, and inside diameter surface of the block
ring.

16. Insert the 1st-reverse clutch hub assembly &

sleeve (1) with a press using the installer 5-8840-
2345-0, setting the six nails of the inside ring to en-
ter the six holes of the hub. 

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2

3

5

4

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