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 "Borg-Warner" cars Rodeo/Passport

6.1.7. 5-step a check point "Borg-Warner" cars Rodeo/Passport
THE GENERAL DATA

Details of 5-step box Borg-Warner of cars Rodeo/Passport

1 – a lock ring
2 – a conducted gear wheel of 5th transfer
3 – a cracker муфты the synchronizer
4 – a pin
5 – a secondary shaft
6 – a bearing holder
7 – a lock ring
8 – the roller persistent bearing with a holder
9 – a bell
10 – амортизирующая the plug
11 – a side scene
12 – a spring and a clamp ball
13 – an epiploon
14 – the information tablet
15 – transitive section картера
16 – сапун
17 – the plug and a shaft of an intermediate gear wheel of a backing
18 – a primary shaft
19 – the bearing
20 – an epiploon of a cover of the bearing and a washer
21 – a bearing cover
22 – a directing bolt and the switch of a signal of a backing
23 – картер
24 – a drain stopper
25 – the back bearing and распорная
26 – the lever of inclusion of 5th transfer and a backing
27 – a plug and a rod of 5th transfer and a backing
28 – a pin
29 – a spring ring and муфта the synchronizer of 5th transfer
30 – the holder of crackers

 

31 – a blocking ring, a nave and crackers of the synchronizer of 5th transfer
32 – a lock ring and a washer
33 – the forward bearing and a persistent washer of an intermediate shaft
34 – a gear wheel of an intermediate shaft
35 – the needle bearing and a holder
36 – a conducted gear wheel of 5th transfer
37 – a blocking ring of the synchronizer of 3rd and 4th transfers
38 – a conducted gear wheel of 3rd transfer
39 – a lock ring
40 – a blocking ring
41 – the directing bearing of a secondary shaft
42 – a blocking ring
43 – a spring, crackers and муфта 3rd and 4th transfers
44 – a plug of switching of 3rd and 4th transfers
45 – blocking муфта and a finger
46 – шестеренчатая sliding муфта a backing and a spring ring
47 – a conducted gear wheel of 2nd transfer
48 – заглушка
49 – a cover
50 – a sealing ring
51 – crackers
52 – a plug of inclusion of 1st and 2nd transfers
53 – a rod
54 – a secondary shaft
55 – a blocking ring
56 – a conducted gear wheel of 1st transfer
57 – a persistent washer, the back bearing and a cover


1st stage of dismantling

PERFORMANCE ORDER
1. Merge oil.
2. Beat out a pin fixing a side scene of a control lever of a check point on a rod of a gear change.
3. Remove transitive section картера a check point together with a side scene.
4. Get from a side scene a spring and a clamp ball. Get from back or transitive section directing pin.
5. Remove the back persistent bearing of a secondary shaft and a bearing holder.
6. Uncover картера transmissions and plugs of inclusion of transfers. Two bolts of a cover are simultaneously directing pins. Before removal of bolts put on them labels that at assemblage to establish on former places.
7. Get the spring ring fixing directing bolt of a rod of inclusion of a reverse gear.
8. Turn out a lock bolt, get a rod with a plug.
9. Put a label of mutual orientation of a cover of the forward bearing rather картера, turn away bolts and uncover.
10. Get from a cover a holder of the forward bearing and a washer. Hook and get an epiploon.
11. Turn a primary shaft and get from картера.
12. Remove from a primary shaft persistent and roller bearings. Remove a holder of the bearing of a secondary shaft. If necessary ослабьте a shaft easy blows of a plastic hammer.
13. Raise and incline a secondary shaft, get a shaft in gathering from картера.
14. Cautiously press the back bearing of an intermediate shaft, preliminary having marked orientation of the bearing concerning a shaft.
15. Displace an intermediate shaft back and having inclined get from картера. Remove the remote plug.
16. Get a pin of a shaft of an intermediate gear wheel of a backing and remove a shaft in gathering with a gear wheel.
17. Press the forward bearing from an intermediate shaft and the directing bearing from a primary shaft.

18. Turn out from картера the switch of a signal of a backing.


Dismantling of a secondary shaft

PERFORMANCE ORDER
1. Remove a washer of the persistent bearing from a forward part of a shaft.
2. Put labels of mutual orientation on муфту and a nave of the synchronizer of 3rd and 4th transfers.
3. Remove the synchronizer of 3rd and 4th transfers in gathering with a blocking ring, муфтой and a nave.
4. Get spring rings, crackers and remove муфту from a nave.
5. Remove a conducted gear wheel of 3rd transfer.
6. Remove a lock ring of a gear wheel of 2nd transfer, a persistent washer and a gear wheel.
7. Press from a shaft the bearing.
8. Remove a persistent washer of a gear wheel of 1st transfer, get a pin, remove a gear wheel and blocking ring.
9. Put labels of mutual orientation муфты the synchronizer of 1st and 2nd transfers and a secondary shaft.
10. Get spring rings and remove crackers with шестеренчатой муфты, remove муфту from a shaft.

Assemblage of a secondary shaft

PERFORMANCE ORDER
1. Grease a shaft and internal surfaces of gear wheels трансмиссионным with oil.
2. Dress муфту the synchronizer of 1st and 2nd transfers on a nave, having combined labels put at dismantling.
3. Establish in муфту 1st transfers three crackers and two spring rings.
The prevention

At assemblage crackers and springs сориентировать in a former order, joints of spring rings should be directed every which way.


4. Establish on a shaft blocking ring and a conducted gear wheel of 2nd transfer.
5. Establish a persistent washer and a lock ring of a gear wheel of 2nd transfer, the washer should come into a flute completely.
6. Establish blocking ring and a conducted gear wheel of 1st transfer, then insert a gear wheel pin.
7. Напрессуйте on a shaft the back bearing.
8. Establish on a shaft other details: a persistent washer of a gear wheel of 1st transfer, a conducted gear wheel of 3rd transfer, the synchronizer of 3rd and 4th transfers. Establish a washer of the back persistent bearing of an intermediate shaft.

Dismantling of the mechanism of management of a check point

PERFORMANCE ORDER
1. Expose crackers and a rod in neutral position.
2. Turn a rod counter-clockwise that crackers left gearing with муфтой. In this position access to a finger opens.
3. Press a rod back against the stop муфты into a plug of inclusion of 1st and 2nd transfers.
4. Beat out a finger and get a rod.
5. Remove plugs, муфту, a finger and crackers.
6. Get an epiploon and a sealing ring.
7. Get from plugs nylon inserts and crackers.
The prevention

Mark a relative positioning of details that at assemblage to establish on former places.



Assemblage

PERFORMANCE ORDER
1. Establish in plugs nylon inserts and crackers.
2. Grease заглушки with hermetic and turn.
3. Grease rods and apertures of rods with technical vaseline. Insert a rod into a cover so that the rod end face was заподлицо with cover edge.
4. Establish a plug of inclusion of 1st and 2nd transfers by acting part towards a back part of a cover. Enter a rod into a plug.
5. Establish in a cover подковообразную a blocking plate муфты and plugs, push a rod in a plug. The widest part blocking муфты should be turned aside from a cover, and the finger муфты should be turned downwards, towards a back part of a cover.
6. Establish a plug of inclusion of 3rd and 4th transfers so that the part of a plug displaced from an axis has been turned towards a back part of a cover. The cracker of a plug of 3rd and 4th transfers should be located under a cracker of a plug of 1st and 2nd transfers.
7. Push a rod through a plug and enter into a forward aperture of a cover.
8. Turn a rod so that the cracker was fixed.
9. Запрессуйте a finger, having combined apertures in a rod and муфте. The finger should be заподлицо with a surface муфты.
10. Establish in a flute of an epiploon of a rod a sealing ring, grease and establish an epiploon.

Box assemblage

PERFORMANCE ORDER
1. Grease an external holder of the bearing of an intermediate shaft with structure fixing from проворачивания (for example Loctite 601), запрессуйте the bearing so that the holder has appeared заподлицо with картером.
2. Grease a persistent washer of an intermediate shaft with technical vaseline and establish a washer so that the washer tooth has come into deepening in картере.
3. Establish картер vertically and enter an intermediate shaft into an aperture for the bearing.
4. Establish the remote plug, grease with technical vaseline the back bearing. Запрессуйте the bearing. The end face of the bearing after запрессовки should act on 3 mm over a surface картера.
5. Establish an intermediate gear wheel of a backing (a flute back), a shaft of a gear wheel and fix a pin.
6. Establish a secondary shaft in gathering.
7. Напрессуйте on a primary shaft a leading gear wheel. Grease with technical vaseline roller bearings and insert them into a flute on a gear wheel. Establish the persistent bearing and a holder.
8. Establish on a secondary shaft blocking ring of the synchronizer of 4th transfer. Establish a holder of the back persistent bearing of a secondary shaft.
9. Establish in картер a leading gear wheel in gathering, having entered into gearing with a blocking ring of the synchronizer.
10. Establish new epiploons in transitive section картера and in a cover of the forward bearing of a primary shaft.
11. Establish the forward bearing. Temporarily establish a cover in картер, hermetic do not put.
12. Establish the lever of inclusion of a reverse gear, wrap a lever axis (grease a carving with non-drying hermetic) and establish a spring ring. Be convinced that the plug has come into gearing with an intermediate gear wheel of a backing.
13. Grease with technical vaseline a holder and the persistent bearing, establish these details in transitive section картера.
14. Temporarily establish (without hermetic) transitive section картера a check point, slightly tighten fastening bolts.
15. Check up axial люфт a secondary shaft, having established a box vertically. To choose люфт it is necessary to create a preliminary tightness in bearings, having wrung out them on 0,025–0,130 mm. Measure axial люфт and pick up a package of the adjusting washers, which thickness on 0,025–0,130 mm (tightness size) more measured люфта.
16. Establish a package of washers under a cover of the forward bearing of a primary shaft. Put on a cover a drop of hermetic RTV. Establish a cover in картер, preliminary having combined labels. Tighten bolts with the moment 18 Н.м. Also check up axial люфт a secondary shaft. Люфт should be absent. If necessary repeat adjustment.
17. Remove transitive section Move муфты synchronizers and a plug to neutral position. Grease with hermetic RTV a demountable surface of a cover картера. Combine plugs with муфтами synchronizers and cautiously establish a cover into place. Centre a cover and insert directing pins. Tighten bolts with the moment 10 Н.м.
The prevention

In correct position the finger connecting a rod and муфту, should be in vertical position. Otherwise repeat actions under item 17.


18. Grease with hermetic transitive section and establish on a secondary shaft.
The prevention

The rod should enter freely into a cover aperture картера.


19. Establish a clamp spring in a side scene, enclose a ball in deepening of a cover of the clamp, corresponding to neutral position. Press a spring and displace a side scene along a rod then establish transitive section картера (or a tail part картера) on картер a check point. Tighten bolts with the moment 34 Н.м.
20. Connect a pin a side scene and a rod. Establish in a side scene амортизирующую the plug. Grease a carving of the switch of a signal of a backing with hermetic and tighten the switch with the moment 20 Н.м.