Isuzu Rodeo UE. Service manual - part 509

7B–68

MANUAL TRANSMISSION

16. Using a 22 mm wrench, remove the backup lamp

switch from the 5–R shift lever side of the case.  Note
that the threads use sealer.
Lift the 5–R lever(9) out of the transmission case.

230RS018

Remove the spring from the case.
Remove the reverse fork and spring assembly(9)
along with the 5–R lever(9).

230RS019

17. Remove the 5th drive gear(10) and blocking ring(10)

from the counter shaft.

18. Remove slip yoke seal(11) and snap ring(11) from the

mainshaft.

226RS100

19. Remove speedometer drive gear(11) and clip(11) by

using speed drive gear puller J–38878.

226RS101

MANUAL TRANSMISSION

7B–69

20. Remove 5th driven gear snap ring.

226RS102

21. Scribe alignment marks on the case and input bearing

retainer and remove the four input shaft bearing
retainer bolts, using a 13 mm wrench.
Note the thread sealer on these bolts.
Remove the input bearing retainer(12), together with
the bearing outer race(12) and shim(s) (12).

226RS103

22. Remove the input shaft assembly(13) from the case

by rotating it until the flat surface on the clutch tooth
ring on the shaft allows it to clear the counter shaft.

226RS104

23. Remove these 4th gear blocking ring, mainshaft

thrust bearing and race, mainshaft needle bearing (15
rollers) and spacer(14) either from the input(13) or
mainshaft.

24. Push the mainshaft rearward to remove the

mainshaft rear bearing outer race(15).

25. Tilt and lift the mainshaft assembly(16) from the case.

226RS105

7B–70

MANUAL TRANSMISSION

226RS106

26. Remove the counter shaft rear bearing retainer by:

f

Bending back the lock tabs with a punch and
hammer.

f

Removing the four bolts, using a 13 mm wrench, or
T–40 bit and ratchet.

f

Removing the retainer(17) and shim(17) from the
case.

226RS107

27. Remove the roll pin(18) that holds the reverse idler

shaft in the case, using a 3/16–inch diameter pin
punch and a hammer.

226RS108

28. Remove the reverse idler assembly by pushing the

shaft rearward and out of the case.  Lift the reverse
idler gear(18) and O–ring(18) out of the case.
Pull out reverse idle shaft(18) rearward.

226RS109

MANUAL TRANSMISSION

7B–71

29. Remove the counter shaft rear bearing outer race(19)

by pushing it rearward.

226RS110

Remove the rear bearing assembly from the counter
shaft by using gear puller J–8433, bearing and gear
puller J–22912–01 and split plate.

226RS111

30. Remove the counter shaft assembly(21) as shown in

the figure from transmission case(22).

226RS112

Inspection and Repair

1. Clean all parts with solvent and dry them with

compressed air.

2. Inspect these parts for cracks and damaged sealing

surfaces:

f

Case

f

Extension housing

f

Shift cover

f

Input bearing retainer

f

Counter shaft rear bearing retainer.

Use a fine mill file to dress minor scratches or burrs.
Replace severely damaged parts.  Replace the
counter shaft rear bearing retainer if the tangs are
broken.

220RS055