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Home >> Isuzu >> 1994 >> Trooper S, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - MUA Series 5-Speed >> Transmission Reassembly

Transmission Reassembly

  1. Mesh countergear assembly with mainshaft and 4th gear shaft assemblies and install into Holding Fixture (J37224) and Holding Base (J3289-20). Install intermediate plate and mainshaft bearing snap ring. See Figure. Install bearing plate. Apply Loctite to bearing plate screws and torque to 11 ft. lbs. (15 N.m) using Torx Bit Wrench No. 45 (J37225).
  2. Install needle bearing, mainshaft reverse gear and reverse block ring. Install 5th-reverse synchronizer assembly with hub facing reverse gear. Mesh 1st-2nd synchronizer with 1st gear and 3rd-4th synchronizer with 3rd gear. Install mainshaft nut and torque to 101 ft. lbs. (137 N.m) using Mainshaft Nut Wrench (J37219). Stake nut in one place.
  3. Install needle bearing, 5th block ring and 5th gear. See Figure. Install counter reverse gear with projection towards intermediate plate. Assemble reverse shaft pin, thrust washer, reverse idler gear and reverse shaft. Install counter 5th gear and reverse shaft assembly together onto intermediate plate. Install countergear ball bearing. Select and install countergear bearing snap ring that will allow minimum clearance between bearing and snap ring. See COUNTERGEAR BEARING SNAP RINGS  table.
    COUNTERGEAR BEARING SNAP RINGS

    Color Thickness - In. (mm)
    White .043 (1.10)
    Yellow .047 (1.20)
    Blue .051 (1.30)
    Pink .055 (1.40)
    Green .059 (1.50)
    Brown .063 (1.60)
  4. Select and install reverse gear shaft snap ring that allows minimum clearance between intermediate plate and snap ring. See REVERSE GEAR SHAFT SNAP RINGS  table.
    REVERSE GEAR SHAFT SNAP RINGS

    Color Thickness - In. (mm)
    White .047 (1.20)
    Yellow .051 (1.30)
    Blue .055 (1.40)
  5. Install thrust washer and lock ball onto mainshaft. Measure clearance between 5th gear and thrust washer. Clearance should be .004-.010" (.10-.25 mm). If clearance is not to specification, select a NEW thrust washer to bring clearance to specification. See SELECTIVE THRUST WASHERS  table. Apply grease to thrust washer and lock ball and install onto mainshaft.
    SELECTIVE THRUST WASHERS

    Color Thickness - In. (mm)
    White .311 (7.90)
    Yellow .315 (8.00)
    Green .319 (8.10)
    Blue .323 (8.20)
  6. Install thrust plate and retainer. On 2WD models, install retainer snap ring, speedometer drive gear, clip and bearing snap ring. On all models, press on ball bearing using Installer (J37223) and a hammer. On 2WD models, install bearing snap ring. On 4WD models, install oil seal collar.
  7. On all models, install 1st-2nd shift arm onto 1st-2nd synchronizer sleeve and 3rd-4th shift arm onto 3rd-4th synchronizer sleeve. See Figure. Install interlock pins into 3rd-4th shift rod and install 3rd-4th shift rod into intermediate plate. Install 1st-2nd shift rod and drive in 1st-2nd and 3rd-4th shift rod into intermediate plate. Install 1st-2nd shift rod and drive in 1st-2nd and 3rd-4th shift arm spring pins.
  8. Assemble reverse inhibitor spring, reverse inhibitor, 5th-reverse shift arm and 5th-reverse shift rod and install assembly into intermediate plate. Drive in spring pin and install spring. Install detent balls, springs and detent spring plate. Torque bolts to 11 ft. lbs. (15 N.m).
  9. On 2WD models, clean transmission case, intermediate plate and extension housing mating surfaces. Apply liquid gasket to transmission case and extension housing mating surfaces. Install intermediate plate to transmission case and extension housing to intermediate plate. Install extension housing bolts and torque to 27-30 ft. lbs. (37-41 N.m).
  10. On 4WD models, clean transmission case, intermediate plate and transfer case mating surfaces. Apply liquid gasket to transmission case and transfer case mating surfaces. Install intermediate plate to transmission case and transfer case to intermediate plate. Install transfer case bolts and torque to 23-35 ft. lbs. (31-47 N.m).
  11. Install transfer countergear bearing snap ring. See Figure. Expand snap ring using snap ring pliers and tap in transfer countergear assembly. Install front output shaft bearing snap ring. Expand snap ring and tap in front output shaft assembly.
  12. Install ball, bearing collar, needle bearing, transfer input gear high-low block ring and high-low synchronizer assembly. Install washer and mainshaft end lock nut. Torque nut to 89-103 ft. lbs. (120-139 N.m) using mainshaft nut wrench. Install mainshaft end ball bearing and mainshaft end bearing snap ring.
  13. Install high-low shift arm onto high-low synchronizer sleeve. Install high-low block, high-low shift rod and select rod assembly. Drive in high-low shift arm spring pin. Engage high-low synchronizer with rear output gear and install interlock pin spring and interlock pin.
  14. Assemble 2nd-4th block, 2nd-4th shift arm, and spring onto 2nd-4th shift rod. Push down interlock pin and install 2nd-4th shift rod into transfer case. Drive in 2nd-4th block spring pin. Install bridge, detent balls, detent springs and detent plugs. Torque plugs to 11-17 ft. lbs. (15-23 N.m).
  15. Install transfer switch and torque to 29 ft. lbs. (39 N.m). Clean transfer case and transfer rear case mating surfaces. Apply liquid gasket to transfer rear case mating surfaces and install onto transfer case. Torque bolts to 21-33 ft. lbs. (29-45 N.m).
  16. Install transfer flange and nut. See Figure. Using Transfer Flange Holder (J27221) and socket wrench, torque nut to specification.
  17. On all models, install speedometer driven gear and torque bolt to specification. Install countergear front bearing snap ring and mainshaft front bearing snap ring. See Figure. Install front cover with oil seal. Coat bolt threads with liquid gasket and torque to specification.
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