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 of late release, 4х4

6.1.6. 5-step a check point of cars of late release, 4х4
THE GENERAL DATA

AMIGO/MU/JAZZ, RODEO/PASSPORT, TROOPER/BIGHORN

Details 5-step a check point of all-wheel drive cars of late release

1 – a speedometer reducer
2 – a flange of a leading shaft
3 – the holder of a forward epiploon
4 – a lock ring of an intermediate shaft of 5th transfer
5 – a lock ring of the bearing
6 – a cover of a distributing column
7 – картер a check point and details картера a distributing box

Details of the internal device 5-step a check point of all-wheel drive cars Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn late release

1 – clamps of rods
2 – a rod, a plug and crackers
3 – the block of gear wheels of 5th and back transfers
4 – an intermediate shaft
5 – primary and secondary shaft with the block of gear wheels

Partition картера and the gear change mechanism

1 – a clamp cover
2 – a clamp spring
3 – a ball
4 – a spring
5 – a rod of inclusion of 5th transfer and a backing
6 – a plug of inclusion of 5th transfer and a backing
7 – a rod of inclusion of 1st and 2nd transfers
8 – a rod of inclusion of 3rd and 4th transfers
9 – a plug of inclusion of 3rd and 4th transfers
10 – a plug of inclusion of 1y th and 2nd transfers
11 – a pin
12 – a partition картера

Preliminary remarks

(Subsection 6.1.5) see.

Dismantling

PERFORMANCE ORDER
1st stage
1. Fix a check point at the stand or a workbench.
2. Merge oil.
3. Remove a reducer of a speedometer and a flange of a leading shaft.
4. Remove a forward epiploon with the holder, a lock ring of an intermediate shaft of 5th transfer and a lock ring of a primary shaft.
5. Turn away bolts of fastening of a distributing box and remove a box.
2nd stage: the Partition and gear change plugs
6. Uncover clamps, get springs and balls by means of a magnetised wire.
7. Get шплинт, remove a spring, a rod and a plug of inclusion of 5th transfer and a backing and blocking of inclusion of a backing.
8. Remove rods and plugs of inclusion of 1/2 and 3/4 of transfers.
The prevention

To take blocking crackers before removal of rods and gear change plugs, fix a corresponding rod прутком.


9. Get blocking crackers from a rod of inclusion of 3/4 transfers.

Assemblage

PERFORMANCE ORDER
1. Establish plugs of 1/2 and 3/4 of transfers, a rod of inclusion of 3/4 transfers, insert pins and establish a rod of 1/2 transfers, зашплинтуйте.
2. Establish a plug of inclusion of 5th transfer and a backing, blocking of inclusion of a backing, a rod of a plug and a spring.
3. Establish a cover of clamps, springs and balls. Tighten bolts of a cover with the moment 15 Н.м.

THE BLOCK OF GEAR WHEELS 5-Й TRANSFER AND THE BACKING

The block of gear wheels of 5th transfer and backing (Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn)


1 – a holder of epiploons
2 – the bearing
3 – a restrictive ring
4 – a persistent plate
5 – a persistent washer and a clamp ball
6 – a lock ring of an intermediate gear wheel of a backing
7 – a lock ring of the bearing
8 – the bearing
9 – a leading gear wheel of 5th transfer
10 – a shaft of an intermediate gear wheel
11 – an intermediate gear wheel of a backing
12 – a persistent washer
13 – a shaft pin
14 – a leading gear wheel of a backing
15 – a conducted gear wheel of 5th transfer
16 – a blocking ring of the synchronizer
17 – the needle bearing
18 – a nut of a nave of the synchronizer
19 – the synchronizer of 5th transfer and a backing
20 – a blocking ring of the synchronizer of a reverse gear
21 – a conducted gear wheel of a backing
22 – the needle bearing
23 – a plate of bearings
24 – a lock ring of the bearing
25 – a partition

Dismantling

The synchronizer of 5th transfer and backing

1 – a nave

2 – a small flute

3 – crackers

4 – spring rings

5 – муфта


Installation of a nave of a leading gear wheel of a backing


PERFORMANCE ORDER
1. Remove a holder of an epiploon and the bearing of an intermediate shaft.
2. Uncover, a washer and a clamp ball.
3. Remove lock rings and press the bearing and a conducted gear wheel of 5th transfer from an intermediate shaft.
4. Remove a shaft of an intermediate gear wheel of a backing, a gear wheel, a persistent washer and a shaft.
5. Remove a leading gear wheel of the backing, blocking ring of 5th transfer and needle bearings.
6. Block synchronizers of 3/4 and 1/2 of transfers, having dressed муфты accordingly on wreaths of 3rd transfer and 1st transfers, and turn away a nave nut.
7. Remove details of the synchronizer of 5th transfer and a backing, operating with two mounts as levers.
8. Get blocking ring of the synchronizer of the reverse gear, a leading gear wheel of a backing and the needle bearing.
9. Turn away bolts with secret шестигранными heads and remove a persistent plate of the bearing.
10. Remove a lock ring of the bearing and a partition.

Assemblage

PERFORMANCE ORDER
1. Establish a partition картера.
2. Tighten bolts of a plate of the bearing with the moment 15 Н.м., preliminary having greased with their structure fixing from отворачивания.
3. Put on a secondary shaft of a gear wheel, the synchronizer of 5th and back transfers, tighten a nut with the moment 128 Н.м. Раскерните a nut.
4. Establish the needle bearing, blocking ring of the synchronizer of 5th transfer and a leading gear wheel of 5th transfer.
5. Establish a leading gear wheel of a backing so that the acting part of a gear wheel has been turned towards a partition. Collect a shaft of an intermediate gear wheel of a backing with gear wheels and washers and a plastic hammer запрессуйте in a partition.
6. Establish the bearing and an adjusting ring which compensates a backlash to 0,15 mm.
7. Establish a washer, a clamp ball, a plate, a restrictive ring, the bearing and an epiploon holder.

PRIMARY, SECONDARY AND INTERMEDIATE SHAFT

Primary, secondary, intermediate shaft 5-step a check point (Amigo/MU/Jazz, Rodeo/Passport, Trooper/Bighorn)

1 – a lock ring of a primary shaft
2 – a primary shaft
3 – the ball bearing
4 – needle bearings
5 – a blocking ring of the synchronizer of 4th transfer
6 – a lock ring of a secondary shaft
7 – the synchronizer of 3/4 transfers
8 – a blocking ring of the synchronizer of 3rd transfer
9 – a leading gear wheel of 3rd transfer
10 – needle bearings
11 – a holder of the needle bearing
12 – the bearing of a secondary shaft
13 – the persistent bearing of a conducted gear wheel of 1st transfer

14 – a conducted gear wheel of 1st transfer
15 – a blocking ring of the synchronizer of 1st transfer
16 – needle bearings
17 – a lock ring of a nave of the synchronizer
18 – the synchronizer of 1/2 transfers
19 – a blocking ring of the synchronizer of 2nd transfer
20 – a conducted gear wheel of 2nd transfer
21 – needle bearings
22 – a secondary shaft
23 – a lock ring
24 – bearings of an intermediate shaft
25 – bearings of an intermediate shaft
26 – an intermediate shaft


Dismantling

PERFORMANCE ORDER
1. Remove a lock ring, a primary shaft, the needle bearing, выпрессуйте the bearing of a primary shaft.
2. Get blocking ring, a lock ring of a secondary shaft and remove the synchronizer of 3/4 transfers.
3. Get the second blocking ring, a leading gear wheel of 3rd transfer, the needle bearing, выпрессуйте a holder of the needle bearing.
4. Выпрессуйте the bearing of a secondary shaft, remove the persistent bearing and a conducted gear wheel of 1st transfer.
5. Remove blocking ring of the synchronizer of 1st transfer, needle bearings and a lock ring.
6. Remove the synchronizer of 1/2 transfers in the gathering, blocking ring of the synchronizer of 2nd transfer, a conducted gear wheel of 2nd transfer and needle bearings.
7. From an intermediate shaft remove a lock ring and press both bearings.

Assemblage

PERFORMANCE ORDER
1. Dress on a secondary shaft the needle bearing and a conducted gear wheel of 2nd transfer. The auxiliary gear wreath of a gear wheel should be turned back.
2. Establish blocking ring of the synchronizer of 2nd transfer and the synchronizer of 1/2 transfers in gathering. A small flute on муфте and a flat surface of a nave should be turned into one party. Check up freedom of longitudinal moving муфты on a nave.
3. Establish an adjusting ring, the needle bearing, blocking ring of the synchronizer, a conducted gear wheel of 1st transfer and the persistent bearing, which obverse part should be turned forward.
4. Напрессуйте the bearing of a secondary shaft and a holder of the needle bearing.
5. Establish the needle bearing of a gear wheel of 3rd transfer, blocking ring of the synchronizer, a conducted gear wheel of 3rd transfer and the synchronizer of 3/4 transfers in gathering. The auxiliary gear wreath of a conducted gear wheel of 3rd transfer should be turned forward. Сориентируйте a nave so that the acting part of a nave has been turned towards ring проточки on an external surface муфты. Check up freedom of longitudinal moving муфты on a nave.
6. Establish an adjusting ring, the needle bearing, blocking ring and a primary shaft.
7. Напрессуйте both bearings also establish a lock ring on an intermediate shaft.
8. Напрессуйте on an intermediate shaft bearings also establish a lock ring.

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 – 9,0–9,8 mm, 3rd and 4th transfers – 9,0–9,9 mm, back and 5th transfers of 9,0-9,9 mm.
2. Measure length of springs of clamps which should be 26,2–26,8 mm for all transfers. For a spring of a clamp of inclusion of a distributing box – 15,3–15,9 mm.
3. Check up elasticity of springs which for clamps of all transfers should be 8,9–9,9 кГс and for the mechanism of inclusion of a distributing box – 6,6–7,6 кГс.
4. Check up a backlash between blocking rings and end faces of gear wreaths of gear wheels. A standard backlash – 0,8–1,5 mm.
5. Check up a backlash between blocking rings and crackers. The backlash should be within 3,51–4,00 mm for 3rd and 4th transfers, for 5th transfer – 4,34–5,00 mm, for the others – 3,59–4,10 mm.
6. Check up a backlash between a nave of the synchronizer and crackers which should be within 0,01–0,03 mm.
7. Check up palpation of a secondary shaft which should not exceed 0,05 mm.
8. Measure internal diameter of conducted gear wheels which should be: for gear wheels of 1st and 3rd transfers of 45,0-45,1 mm, for a gear wheel of 2nd transfer – 52,0–52,1 mm, for a gear wheel of a distributing box and a backing – 48,0–48,1 mm and for a gear wheel of 5th transfer – 32,0–32,10 mm.
9. Check up a backlash between the plug and shaft of an intermediate gear wheel of a backing (norm of 0,041-0,150 mm).
10. Check up люфт in gearing of gear wheels. Люфт, measured on naves of synchronizers should be within 0,0–0,20 mm, люфт backing gear wheels – 0,0–0,3 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.

Check point assemblage


PERFORMANCE ORDER
1. On a demountable plane картера a distributing box put hermetic.
2. Translate the synchronizer демультипликатора a distributing box in position "4Н". Turn ползун a distributing box so that the ledge on ползуне has come into a side scene groove.
3. Establish shaft and a partition in картер a check point and a distributing box. Sample on a head part of a rod should be combined with terminator deepening in a cover картера a distributing box.
4. Tighten fastening bolts картера a distributing box to картеру a check point with the moment 37 Н.м.
5. Establish lock rings of bearings of intermediate and primary shaft.
6. Put hermetic on forward section картера and запрессуйте a new epiploon. Establish section and tighten bolts with the moment 19 Н.м.
7. Establish a flange of a leading shaft and a speedometer reducer.