Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1812
MSG MODEL (2WD) 7B-25
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness
mm(in)
Standard
Limit
1st-2nd
9.6-9.8 (0.378-0.386)
9.0 (0.354)
3rd-4th
6.95-7.2 (0.273-0.283)
6.5 (0.256)
Rev.-5th
6.8-6.9 (0.268-0.272)
6.3 (0.248)
DETENT SPRING FREE LENGTH
Use a venier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the detent
spring must be replaced.
Detent Spring Free Length
mm(in)
Standard
Limit
25.6 (1.01)
23.6 (0.93)
DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension
N(kg/lb)
Compressed
Height mm(in)
Standard
Limit
22.1 (0.870)
61.8-65.7
(6.3-6.7/13.9-14.8)
55.9
(5.7/12.6)
BLOCK RING AND DOG TEETH
CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance
mm(in)
Standard
Limit
1st,2nd
2.0 (0.078)
1.3 (0.051)
3rd, 4th, 5th
1.5 (0.059)
0.8 (0.032)
7B-26 MSG MODEL (2WD)
BLOCK RING AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance
mm(in)
Standard
Limit
1st,2nd
3.46-3.74 (0.136-0.147)
3rd, 4th, 5th
3.51-3.79 (0.138-0.149)
4.0 (0.157)
CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance
mm(in)
Standard
Limit
0.01 - 0.19 (0.0004 - 0.0075)
0.3 (0.012)
MAINSHAFT RUN - OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central
portion run-out.
If the measured mainshaft run-out exceeds the specified
limit, the mainshaft must be replaced.
Mainshaft Run - Out
mm(in)
Limit
Less than 0.03 (0.0012)
GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter
mm(in)
Standard
Limit
1st
Rev.
45.00-45.01
(1.7717-1.7720)
45.10 (1.7756)
2nd
3rd
41.00-41.01
(1.6142-1.6146)
41.10 (1.6181)
5th
34.03-34.04
(1.3398-1.3402)
34.10 (1.3425)
MSG MODEL (2WD) 7B-27
REVERSE IDLER GEAR AND IDLER
GEAR SHAFT CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to measure the idler gear inside
diameter.
3. Calculate the idler gear and idler gear shaft clearance.
Idler gear inside diameter - idler gear shaft diameter = idler
gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the idler
gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance
mm(in)
Standard
Limit
0.041 - 0.074 (0.0016 - 0.0029)
0.150 (0.0059)
CLUTCH HUB SPLINE PLAY
1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right and
the left.
Note the dial indicator reading.
It the measured value exceeds the specified limit, the clutch
hub must be replaced.
Clutch Hub Spline Play
mm(in)
Standard
Limit
0.019 (0 - 0.075)
0.20 (0.0079)
7B-28 MSG MODEL (2WD)
BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
mm(in)
Limit
0.2 (0.0079)
FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.
Oil Seal Installation
1. Use the oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer : 5-8522-0042-0 (J-26540)
2. Apply engine oil to the oil seal lip.
REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.
Oil Seal Installation
1. Use the oil seal installer to install the oil seal to the rear
cover.
Oil Seal Installer : 9-8522-1273-0 (J-29769)
2. Apply engine oil to the oil seal lip.
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