Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1826

MSG MODEL (4WD) 7B-81

REASSEMBLY OF INTERNAL PARTS (TRANSFER)

MAJOR COMPONENT (2)

Reassembly Steps

1. Transfer case assembly
2. Transfer side case assembly

7B-82 MSG MODEL (4WD)

MINOR COMPONENTS

INTERMEDIATE PLATE, TOP GEAR SHAFT, MAINSHAFT GEAR WITH COUNTER GEAR

Reassembly Steps

1. Mainshaft

! 2. Needle bearing
! 3. 2nd gear

4. 2nd block ring

! 5. 1st-2nd synchronizer assembly

6. 1st block ring

! 7. Needle bearing collar
! 8. Needle bearing
! 9. 1st gear
!10. 1st gear thrust washer
!11. Mainshafr ball bearing
!12. Needle bearing
!13. 3rd gear

14. 3rd block ring

!15. 3rd-4th synchronizer assembly

!16. Mainshaft snap ring

17. 4th block ring
18. Counter gear
19. Front ball bearing
20. Bearing snap ring

!21 Rear ball bearing

22. Needle bearing

!23. Ball bearing
!24. Top gear shaft

25. Top gear shaft snap ring

!26. Reverse idler shaft

27. Bearing snap ring
28. Bearing snap ring

MSG MODEL (4WD) 7B-83

Important Operations

2. Needle Bearing

3. 2nd Gear

1) Apply the engine oil to the 2nd needle bearing and the 2nd

gear.

2) Install the needle bearing and the 2nd gear to the mainshaft.

The dog teeth of the 2nd gear must be facing the rear side

of the transmission.

5. 1st-2nd synchronizer assembly

(1) The side of the clutch hub with the

2

oil groove should be

turned to the 2nd gear side.

1

: Oil groove

2

: Oil groove Forward

(2) Check that the inserts are fitted properly into the insert

grooves in the blocker ring and that the insert spring is fitted

to the insert keys as shown in this figure.

Then check that the clutch hub and sleeve slide smoothly.

(3) Install the synchronizer assembly on the shaft, so that face

of sleeve with light chamfer on the outer edge is turned to

the front of transmission.

3

; Insert key

4

; Insert spring

5

; Clutch hub

7. Needle Bearing Collar
Use a bench press and the collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)

7B-84 MSG MODEL (4WD)

8. Needle Bearing

9. 1st Gear

1) Apply the engine oil to the 1st needle bearing and the 1st

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 1st gear must be facing the front side

of the transmission.

10.1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the front of the
transmission.

11.Mainshaft Ball Bearing

1) Apply the engine oil to the ball bearing inside circumference.

2) Use a bench press and the bearing installer to install the

bearing.

The bearing snap ring groove must be facing the front of the

transmission.

Bearing Installer : 5-8840-0015-0 (J-22912-01)

12.Needle Bearing

13.3rd Gear

1) Apply the engine oil to the 3rd needle bearing and the 3rd

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 3rd gear must be facing the front side of

the transmission.

15.3rd-4th Synchronizer Assembly

1) Apply the recommended lubricating oil to the clutch hub

spoine.

2) Install the synchronizer assembly to the mainshaft.

The sleeve light chamfering

1

and the clutch hub heavy

boss

2

must be facing the rear of the transmission.