Isuzu Truper - Isuzu Trooper
1. The maintenance instruction
2. Maintenance service
3. Engines
4. System of decrease in toxicity
5. Fuel system
6. Transmission and a running gear
   6.1. A manual transmission
      6.1.1. The switch of a signal of a backing
      6.1.2. A speedometer reducer
      6.1.3. Removal and manual transmission installation
      6.1.4. 4-step a check point for rear-wheel cars
      6.1.5. 5-step a check point of cars Trooper/Bighorn of early release, 4х4
      6.1.6. 5-step a check point of cars of late release, 4х4
      6.1.7. 5-step a check point "Borg-Warner" cars Rodeo/Passport
      6.1.8. Coupling
   6.2. Automatic transmission
   6.3. A running gear
7. A suspension bracket and a steering
8. Brake system
9. A body
10. A body electric equipment
11. Diagnostics of malfunctions
12. Electroschemes





Isuzu Trooper>> Transmission and running gear>> Manual transmission>> 4-step a check point for rear-wheel cars

6.1.4. 4-step a check point for rear-wheel cars
THE GENERAL DATA

Details 4-step a check point

11 – primary, secondary, intermediate shaft of a check point and the block of gear wheels

1 – the case of a control lever of a check point
2 – выжимной the bearing and a bearing holder
3 – the lever of deenergizing of coupling
4 – a forward epiploon of a check point

 

5 – a spring washer
6 – a lock ring
7 – a conducted gear wheel of a drive of a speedometer
8 – the switch of a signal of a backing
9 – a back cover
10 – an epiploon

Preliminary remarks

Before dismantling absolutely wash up картер a check point, without supposing dirt hit inside. Before check all details of a check point should be washed out and dried.

At assemblage of details of the mechanism of a check point grease all epiploons, needle bearings (for their deduction) with oil SAE-30 or technical vaseline. Application консистентной greasings for bearings of naves is not supposed. All epiploons and consolidations are made from неопренового rubber, therefore to wash out them in solvents it is forbidden. Before assemblage carefully clear all female threads and grease them трансмиссионным with oil. Carter is cast from an aluminium alloy, therefore at заворачивании in картер bolts their warp is not supposed, the carving otherwise will be broken. At use of old spring rings internal lock rings unclench, and external lock rings draw in.

Dismantling

PERFORMANCE ORDER
Check point dismantling (1st stage)
1. Remove the case of the mechanism of management of a check point, get the lever.
2. Remove the holder of a forward epiploon, an epiploon and a spring washer.
3. Remove a lock ring of the forward bearing.
4. Remove a reducer of a speedometer and the switch of a signal of a backing.
5. Remove a back cover and an epiploon.
6. Get a primary shaft, secondary and intermediate shaft in gathering with gear wheels.
Check point dismantling (2nd stage)
7. Get persistent rings of an intermediate gear wheel of a backing.
8. Turn away a bolt of a shaft of an intermediate gear wheel, remove a lock plate and get a shaft of a gear wheel of a backing.
9. Remove a persistent plate, a spring and a clamp ball.
10. Remove a rod and a plug of inclusion of a backing.
11. Get blocking crackers and remove rods of inclusion of 4/3 and 1/2 of transfers.
12. Remove plugs of inclusion of 4/3 and 1/2 of transfers.
13. Get a lateral pin of a partition.
14. Remove an external spring ring of an intermediate gear wheel of a backing, a gear wheel of a drive of a speedometer, шпонку, an internal lock ring and a gear wheel.
15. Turn on самоподжимную a nut of a secondary shaft and remove a washer.
16. Turn on самоподжимную a nut of an intermediate shaft and remove a washer.
17. Remove from shaft an internal partition.
18. Get a lock ring of the bearing of an intermediate shaft.
19. Get a lock ring of the bearing of a secondary shaft.
20. From an intermediate shaft remove: a leading gear wheel of a backing, the plug, the back bearing and needle bearings.
21. Remove a primary shaft, выпрессуйте the bearing and get needle bearings.
22. Remove blocking ring of the synchronizer of 3rd and 4th transfers, a forward lock ring of a shaft, a nave and муфту the synchronizer of 3rd and 4th transfers.
23. Remove blocking ring of the synchronizer of 3rd transfer, a conducted gear wheel of 3rd transfer and the needle bearing.
24. Remove the bearing of a secondary shaft, the persistent washer, a conducted gear wheel of 1st transfer, the needle bearing and the plug.

25. Remove from a secondary shaft blocking ring of the synchronizer of 1st and 2nd transfers, a nave and муфту the synchronizer of 1st and 2nd transfers, blocking ring of the synchronizer of 2nd transfer, a conducted gear wheel of 2nd transfer and the needle bearing.


Check

PERFORMANCE ORDER
1. Check up a thickness of plugs of inclusion of transfers in a place of contact with муфтой the synchronizer. A thickness of a plug of inclusion of 1st and 2nd transfers – 7,8–7,9 mm, 3rd and 4th transfers – 7,1–7,2 mm, plugs of inclusion of a reverse gear – 6,8–6,9 mm.
2. By a calliper measure length of springs of clamps. Length of springs of a clamp of 1st, 2nd, 3rd and 4th transfers – 27,5–30,5 mm, a reverse gear of 24,7-27,7 mm.
3. Check up elasticity of a spring which should be for clamps of 1st, 2nd, 3rd and 4th transfers 4,0–4,2 кГс and for clamps of a reverse gear 6,3–6,7 кГс.
4. Check up a backlash between blocking rings and an end face of a gear wreath of gear wheels. A standard backlash – 0,8–1,5 mm.
5. Check up a backlash between blocking rings and crackers. A standard backlash – 3,51 4,00 mm.
6. Check up a backlash between a nave of the synchronizer and crackers. The backlash should be within 0,01–0,3 mm.
7. Check up palpation of a secondary shaft which should not exceed 0,03 mm.
8. Measure internal diameter of gear wheels. Norm: for gear wheels of 1st transfer and a backing of 45,0-45,1 mm, for gear wheels of 2nd and 3rd transfers – 41,0–41,1 mm.
9. Check up a backlash between the plug and shaft of an intermediate gear wheel of a backing (norm of 0,041-0,15 mm).
10. Check up люфт in gearing of conducted and leading gear wheels. Люфт in gearing of gear wheels with 1st on 4th transfer should be within 0,0–0,20 mm.
11. Replace details which do not meet the specified requirements.

Synchronizer assemblage (4-step a check point)

1 – шпонка

2 – a spring

3 – муфта


Assemblage of the synchronizer of 1st and 2nd transfers (4-step a check point)

1 – the big facet

2 – a small facet

3 – forward

4 – back


Assemblage of the synchronizer of 3rd and 4th transfers (4-step a check point)

1 – forward

2 – a small facet

The prevention

Forward and back needle bearings of a secondary shaft are interchangeable. That rollers were not scattered, before assemblage put in bearings greasing.


Assemblage

PERFORMANCE ORDER
1. Establish on a secondary shaft needle bearings.
2. Establish a conducted gear wheel of 2nd transfer so that конусная the gear wheel part has been turned back.
3. Establish on a secondary shaft the needle bearing. Establish a conducted gear wheel of 1st transfer so that конусная the gear wheel part has been turned forward.
4. Establish a persistent washer a lubricant flute forward. Напрессуйте on the secondary basic bearing.
5. Establish needle bearings. Establish a conducted gear wheel of 3rd transfer, blocking ring and the synchronizer of 3rd and 4th transfers.
6. Establish a lock ring and measure a backlash between a lock ring and a blocking ring of the synchronizer which Backlash should be within 0,0–0,05 m. it is regulated by selection of a lock ring.
7. Establish blocking ring of the synchronizer of 3rd both 4th transfers and the needle bearing.
8. Запрессуйте the forward basic bearing of a secondary shaft so that the flute under a spring ring has been turned forward. Establish the back bearing of an intermediate shaft, the flute under a lock ring of the bearing should be turned back.
9. Establish needle bearings and an internal partition.
10. Establish a lock ring of the bearing of a secondary shaft.
11. Establish a lock ring of the bearing of an intermediate shaft.
12. Establish the plug of an intermediate shaft, a backing gear wheel, a washer and wrap a nut. Tighten a nut of a shaft with the moment 100–120 Н.м.
13. Establish on a secondary shaft a washer and tighten a nut with the moment 100–120 Н.м.
14. Establish on a shaft an intermediate gear wheel, a lock ring, шпонку, a leading gear wheel of a speedometer and the second lock ring.
15. Establish a shaft of an intermediate gear wheel in gathering, insert a lock plate, tighten a bolt with the moment 34 Н.м.
16. Insert a pin, establish plugs of inclusion of all transfers, tighten a bolt with the moment 22 Н.м.
17. Establish a rod and a plug of inclusion of a backing, a clamp ball, a spring and a persistent plate.
18. Establish a persistent plate of a gear wheel of a backing so that фланцевая the washer part densely rested against a fillet on a partition. Establish an intermediate gear wheel of a backing so that the facet on teeths has been turned outside.
19. Establish a gear wheel of a backing and a persistent washer.

Definitive assemblage of a check point

PERFORMANCE ORDER
1. Establish an epiploon in a back cover.
2. Establish in картер a check point the collected secondary, intermediate and primary shaft. At installation of a secondary shaft it is forbidden to make the big effort.
3. Establish a back cover, tighten bolts with the moment 42 Н.м.
4. Establish the switch of a signal of a backing, a reducer of a speedometer and a lock ring of the forward bearing of a secondary shaft.
5. Establish a spring washer, a forward epiploon and the holder tighten bolts with the moment 22 Н.м.
6. Establish the lever of deenergizing of coupling, a holder, выжимной the bearing and the mechanism.