Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual — part 1832
MSG MODEL(4WD) 7B-105
2) NOISY OPERATION
Checkpoint
Trouble Cause
Countermeasure
Replenish or replace the
engine oil
Insufficient or improper engine
oil
NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)
Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)
Worn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)
Gears (Growling, humming, or
grinding)
Worn, chipped, or cracked
gear(s)
NG
NG
NG
NG
OK
OK
OK
OK
Engine oil (Metallic rattling)
7B-106 MSG MODEL (4WD)
2. HARD SHIFTING
Checkpoint
Trouble Cause
Countermeasure
Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operation
Repair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper engine
oil
OK
OK
NG
NG
NG
NG
OK
OK
Engine oil
Synchronizer assembly
Shift arm and synchronizer
sleeve
Replace the worn parts
Replace the worn parts
Worn synchronizer parts
Worn shift arm and/or
synchronizer sleeve groove
Mainshaft and countershaft
thrust play
Replace the worn parts
Replace the shift rod and/or
the quadrant box
Worn thrust washer, collar,
and/or gear thrust faces
Worn shift rod and/or sliding
faces
OK
NG
NG
NG
NO
OK
OK
Shift rod and quadrant box
sliding faces, and other parts
MSG MODEL(4WD) 7B-107
3. WALKING OR JUMPING OUT OF GEAR
Checkpoint
Trouble Cause
Countermeasure
Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent spring
Repair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OK
NG
NG
NG
NG
OK
OK
Change lever play
Mainshaft splines
Synchronizer clutch hub
splines
Mainshaft and countershaft
thrust play
Replace the main shaft and
the synchronizer clutch hub
Replace the worn parts
Worn splines
Worn thrust washer, collar,
and/or gear thrust faces
Bearings (Mainshaft,
countershaft, and individual
gears)
Replace the bearing(s)
Replace the worn parts
Worn or broken bearing(s)
Worn shift arm and/or
synchronizer sleeve groove
OK
NG
NG
NG
NO
OK
OK
Shift arm and synchronizer
sleeve
7B-108 MSG MODEL (4WD)
4. OIL LEAKAGE
Checkpoint
Trouble Cause
Countermeasure
Casting parts (Transmission
case, quadrant box, etc.)
Engine oil
Replace the casting parts
Replace the engine oil
Casting cracked or holed
Improper engine oil
Drain plug and/or filler plug
Tighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OK
OK
NG
NG
NG
NG
OK
OK
Oil level
Rear cover oil seal and yoke
seating surface with oil seal
Air breathe
Replace the oil seal and/or the
flange yoke
Install the air breather Replace
the air breather
Worn or scratched oil seal
and/or worn flange yoke
seating surface with oil seal
Air breather not installed Air
breather clogged
Front cover oil seal and top
gear shaft seating surface with
oil seal
Replace the oil seal and/or the
top bear shaft
Replace the gasket(s)
Worn or scratched oil seal
and/or worn top gear shaft
seating surface with oil seal
Defective or improperly
installed gasket(s)
OK
NG
NG
NG
NO
OK
OK
Gaskets
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