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>> 5-step a check point of cars Trooper/Bighorn of early release, 4х4

6.1.5. 5-step a check point of cars Trooper/Bighorn of early release, 4х4
THE GENERAL DATA

Details 5-step a check point of all-wheel drive cars Trooper/Bighorn of early release

1 – the switch of a signal of a backing
2 – lateral картер a distributing box
3 – выжимной the bearing and a holder
4 – the lever of deenergizing of coupling
5 – the holder of a forward epiploon
6 – a spring washer
7 – a lock ring
8 – a speedometer reducer
9 – картер a check point
10 – back section картера a check point
11 – a secondary shaft, an intermediate shaft of the block of gear wheels of back and 5th transfers

Details 5-step a check point of cars Trooper/Bighorn of early release

1 – a cover of clamps
2 – a spring
3 – a ball
4 – a rod of inclusion of 5th transfer
5 – a plug of inclusion of 5th transfer
6 – a rod of inclusion of 1st and 2nd transfers
7 – a rod of inclusion of 3rd and 4th transfer
8 – a plug of inclusion of 3rd and 4th transfer
9 – a plug of inclusion of 1st and 2nd transfers
10 – a pin and заглушка
11 – a nut
12 – a nave
13 – a gear wheel
14 – a holder of the needle bearing
15 – the gear wheel plug
16 – a lock ring
17 – a lock ring of transitive section картера
18 – the average bearing of a secondary shaft
19 – a bolt маслопровода
20 – маслопровод
21 – transitive section картера
22 – the back bearing of a secondary shaft
23 – a lock ring of the bearing
24 – a persistent ring
25 – a fixing ring
26 – a persistent ring of 5th transfer
27 – a persistent washer of 5th transfer
28 – a counternut of an intermediate shaft of 5th transfer
29 – a washer
30 – the bearing
31 – a conducted gear wheel of a reverse gear
32 – a leading gear wheel of 5th transfer with a wreath
33 – the needle bearing
34 – a blocking ring of the synchronizer
35 – a nut of a secondary shaft
36 – a washer
37 – the synchronizer of back and 5th transfer
38 – a conducted gear wheel of 5th transfer
39 – the needle bearing

41 – a persistent washer of an intermediate gear wheel of a backing
42 – an intermediate gear wheel of a backing
43 – a washer
44 – a partition
45 – a lock ring of a leading shaft
46 – a gear wheel of direct (4th) transfer with a wreath
47 – the bearing
48 – the needle bearing
49 – a blocking ring of the synchronizer of 3rd and 4th transfer
50 – a lock ring of a secondary shaft
51 – the synchronizer of 3rd and 4th transfers
53 – a conducted gear wheel of 3rd transfer with a wreath
54 – the needle bearing
55 – the block of gear wheels of 1st and 2nd transfers
56 – a persistent washer
57 – the bearing of a secondary shaft
58 – the bearing plug
59 – a persistent washer
60 – a conducted gear wheel of 1st transfer with a wreath
61 – the bearing
62 – the bearing plug
63 – a blocking ring of the synchronizer of 1st and 2nd transfers
64 – the synchronizer of 1st and 2nd transfers
65 – a blocking ring of the synchronizer of 1st and 2nd transfers
66 – a conducted gear wheel of 2nd transfer with a wreath
67 – the needle bearing
68 – an intermediate gear wheel of a backing
69 – the bearing of an intermediate shaft
70 – an intermediate shaft
71 – a lock ring
72 – the bearing of an intermediate shaft of a check point
73 – an adjusting washer
74 – клиновая a spring
75 – a shaft of an intermediate gear wheel


Preliminary remarks

Before dismantling absolutely wash out 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 which is dissolved in трансмиссионном oil at work of the mechanism of a check point. Application консистентной greasings for bearings of naves is not supposed. 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. At use of old spring rings internal lock rings unclench, and external lock rings draw in. Before assemblage all details dip in трансмиссионное oil.

Dismantling

PERFORMANCE ORDER
1. Remove the switch of a signal of a backing, lateral картер a distributing box, выжимной the bearing and a holder.
2. Remove the lever of deenergizing of coupling, forward section картера, a spring washer and a lock ring of the forward bearing of a secondary shaft.
3. Remove a speedometer reducer, get a lock plate and a remote washer from an intermediate shaft of 5th transfer.
4. Turn away cover bolts картера a distributing box and get from картера a check point a secondary shaft, an intermediate shaft of the block of gear wheels of back both 5th transfer and a primary shaft. Shaft and a partition will be in картере a distributing box.
Secondary shaft, intermediate shaft of the block of gear wheels of back both 5th transfer and primary shaft
5. Uncover clamps, get springs and balls by means of a magnetised wire.
6. Fix rods прутком, having rested against a rod end face to avoid breakages. Get from rods of all transfers crackers. Remove rods and gear change plugs.
7. Turn out заглушки and get a pin.
8. Turn away a nut of a nave of a tail part of a secondary shaft, remove a nave, a gear wheel, the needle bearing, a holder and a lock ring.
9. Get a lock ring of the bearing of a secondary shaft of a check point, remove the bearing, turn out a bolt маслопровода and remove маслопровод.
10. Remove from shaft intermediate section картера.
11. Remove the first lock ring, a persistent ring and the second lock ring, remove a lock ring of a gear wheel of 5th transfer and a washer.
12. Turn away a nut of an intermediate shaft of 5th transfer, remove a washer and the shaft bearing. Remove an intermediate gear wheel of 5th transfer (the bearing and a gear wheel to remove трехлапным a stripper).
13. Remove a conducted gear wheel of 5th transfer with a cone, needle bearings and a blocking ring of the synchronizer.
14. Dress муфты synchronizers of 1/2 and 3/4 of transfers on conducted gear wheels of 1st and 3rd transfers accordingly, turn away a nut of a secondary shaft and remove a washer.
15. Remove the synchronizer of back and 5th transfers in gathering, remove a gear wheel of a backing and the needle bearing.
16. Turn away a nut of a shaft of a gear wheel of a backing, remove a gear wheel and persistent washers.
17. Remove from shaft a partition.
18. From a primary shaft of a check point get a lock ring and remove a gear wheel. Выпрессуйте the bearing.
19. Remove from a primary shaft the needle bearing and blocking ring of 3rd and 4th transfers.
20. Get from a secondary shaft a lock ring, remove details of the synchronizer of 3rd both 4th transfers and blocking ring of 3rd transfer.
21. Remove a conducted gear wheel of 3rd transfer in gathering with a cone and needle bearings.
22. Gear wheels and bearings of a secondary shaft should be removed by means of a press and a stripper.
23. Выпрессуйте the bearing of a secondary shaft. Get the bearing plug, a persistent washer, remove a gear wheel of 1st transfer with a cone, the needle bearings, the second plug, the first blocking ring of the synchronizer of 1st and 2nd transfers, details of the synchronizer of 1st and 2nd transfers, the second blocking ring and a conducted gear wheel of 2nd transfer.
24. Get from a gear wheel of 2nd transfer needle bearings.
25. Press from an intermediate shaft a gear wheel and the bearing. Remove lock rings of forward and back bearings of a shaft, remove клиновую a spring and turn out a shaft.

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 – 6,5–7,2 mm, plugs of inclusion of a distributing box – 6,0–6,8 mm, back and 5th transfers of 6,3-6,9 mm.
2. Measure length of springs of clamps. Length of springs of a clamp of 1st, 2nd, 3rd and 4th and back transfers a free condition – 25,0–27,7 mm, a distributing box of 41,0-43,0 mm.
3. Check up elasticity of springs which should be for clamps of 1st, 2nd, 3rd and 4th and back transfers 6,3–6,7 кГс and for a distributing box 9,0–11 кГс.
4. Check up a backlash between blocking rings and end faces of gear wreaths of gear wheels. A standard backlash: for gear wheels of 1st and 2nd transfers – 0,8–1,7 mm, for gear wheels of 3rd and 5th transfers – 0,8–1,7 mm, 4th transfers – 0,8–1,3 mm.
5. Check up a backlash between blocking rings and crackers. The backlash should be within 3,51–4,00 mm.
6. Check up a backlash between a nave of the synchronizer and crackers. The backlash should be within 0,01–0,03 mm.
7. Check up palpation of a secondary shaft (should not exceed 0,05 mm).
8. Measure internal diameter of gear wheels which should be: for 1st transfer and a backing of 45,0-45,1 mm, for gear wheels of 2nd and 3rd transfers – 41,0–41,1 mm, for an intermediate gear wheel of a distributing box – 33,0–33,1 mm and for a gear wheel of 5th transfer – 32,03–32,10 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. With the help стрелочного the indicator check up люфт in gearing of gear wheels. Люфт, measured on synchronizer naves should be within 0,0–0,20 mm, люфт backing gear wheels – 0,062–0,200 mm.
11. Check up люфт in ball bearings which should not exceed 0,2 mm.
12. Replace details which do not satisfy to the specified norms.

Assemblage

PERFORMANCE ORDER
1. Establish on a secondary shaft needle bearings of 2nd transfer. Establish a conducted gear wheel of 2nd transfer so that конусная the gear wheel part has been turned back.
2. Establish the first blocking ring and the synchronizer of 1st and 2nd transfer in gathering. Parallel oil flutes on a nave of the synchronizer and the big facet on муфте the synchronizer should be turned into one party. Be convinced that crackers have come into flutes on a blocking ring. Check up freedom of longitudinal moving муфты on a nave. Establish the second blocking ring of the synchronizer of 1st and 2nd transfer.
3. Напрессуйте on a shaft a holder of the needle bearing, using special оправкой.
4. Establish the needle bearings, a conducted gear wheel of 1st transfer with details of the synchronizer and a persistent washer so that the lubricant flute of a persistent washer has been turned forward.
5. Напрессуйте on a secondary shaft the radial bearing. Establish a persistent washer of a conducted gear wheel of a backing so that the lubricant flute of a persistent washer has been turned back.
6. Напрессуйте a holder of the needle bearing. Establish the needle bearings, a conducted gear wheel of 3rd transfer with a cone and a blocking ring of the synchronizer of 3rd and 4th transfers.
7. Establish details of the synchronizer of 3rd and 4th transfers so that the extended party of a nave has been turned to a small facet on муфте the synchronizer. Measure a backlash between shaft and a nave of the synchronizer of 3rd and 4th transfers, establish a lock ring, having picked up it on a thickness.
8. Establish the second blocking ring of the synchronizer of 3rd and 4th transfers, напрессуйте needle bearings and the bearing of a primary shaft of a check point. Establish a lock ring of the bearing.
9. Establish a primary shaft of a check point.
10. Напрессуйте forward and back bearings of an intermediate shaft and a backing. Establish lock rings of bearings.
11. Establish an intermediate shaft of 5th transfer, a leading gear wheel of a backing and a shaft of an intermediate gear wheel of a backing. Wrap a bolt of a shaft with the moment 22 Н.м.
12. Establish in a partition картера rings of the radial bearing of a secondary shaft and the bearing of a gear wheel of 5th transfer. Combine a secondary shaft and an intermediate shaft of 5th transfer with apertures in a partition by means of special оправки.
13. Establish a persistent washer of an intermediate gear wheel of a backing, the plug, the second persistent washer, wrap a nut. Tighten a nut with the moment 120 Н.м.
14. Establish in a backing gear wheel needle bearings, dress a gear wheel on a secondary shaft.
15. Establish details of the synchronizer of 5th and back transfers so that, the extended party of a nave has been turned to the big facet on муфте the synchronizer.
16. Establish a washer and wrap the first nut of a secondary shaft. Tighten a nut with the moment 140 Н.м.
17. Establish blocking ring of 5th transfer, a gear wheel of 5th transfer with a cone, the needle bearing and a persistent washer.
18. Establish persistent and lock rings so that locks of these rings were mutually perpendicular. Establish a restrictive ring and a lock ring of the bearing of a secondary shaft.
19. Establish an intermediate gear wheel of 5th transfer, the bearing, a flat washer and tighten the second nut of a secondary shaft with the moment 140 Н.м.
20. Establish intermediate section картера, маслопровод and tighten a bolt маслопровода with the moment 20 Н.м.
21. Establish the central bearing of a secondary shaft and a lock ring.
22. Establish a lock ring, a holder, the needle bearing, a gear wheel and a nave of a tail part of a secondary shaft, tighten the third nut of a shaft with the moment 140 Н.м.
23. Establish a pin and заглушку.
24. Establish plugs and rods of inclusion of 1/2 and 3/4 of transfers and insert crackers with springs.
25. Establish a plug and a rod of inclusion of 5th and back transfers.
26. Establish balls, springs and a cover of clamps of rods, tighten bolts of a cover with the moment 22 Н.м.