Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1831
MSG MODEL (4WD) 7B-101
Important Operations
1. Adaptor Case Intermediate Plate with Gear Assembly
Apply recommended liquid gasket or its equivalent to the
adaptor case fitting surfaces.
2. Transfer Case Assembly and Gasket
1) Install the new gasket and the transfer case assembly to the
adaptor case with gear assembly.
Take care not to damage the bearing and the adaptor case
bore.
2) Tighten the transfer case bolts to the specified torque.
Transfer Case Assembly Bolt
Torque
N
⋅m(kgf⋅m/lb⋅ft)
37.2
± 7.8 (3.8 ± 0.8 / 27.5 ± 5.8)
Transfer Counter Gear Thrust Clearance Adjustment
3) Loosen the lock plate bolts that semi-tightened on transfer
case assembling procedures in minor component.
4) Push the counter shaft end toward the adaptor case until it
to stop.
5) Use the depth gauge or the vernier caliper to measure the
counter shaft end depth
A
.
6) Select the distance plate from the measured values from
the table as next page.
Refference : Counter Shaft Thrust Clearance
mm(in)
0.1 - 0.35 (0.004 - 0.014)
7B-102 MSG MODEL (4WD)
mm(in)
Thickness of
Distance plate
Measured value (A)
Marking color
3.6 (0.142)
3.7-3.95
(0.146-0.156)
Red
3.8 (0.150)
3.9-4.15
(0.154-0.163)
Orange
4.0 (0.157)
4.1-4.35
(0.161-0.171)
Yellow
4.2 (0.165)
4.3-4.55
(0.169-0.179)
Green
4.3 (0.169)
4.4-4.65
(0.173-0.183)
Blue
3. Transmission Case
1) Apply the engine oil to the transmission case top gear shaft
ball bearing fitting faces.
2) Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4. Bearing Snap Ring
Pull the top gear shaft from the transmission case until the ball
bearing snap ring groove protrudes from the transmission case
front cover fitting face.
Use a pair of snap ring pliers to install the snap ring to the ball
bearing.
6. Front Cover with Oil Seal
1) Apply a recommended liquid gasket or equiverent to the bolt
threads.
2) Install the new gasket and the front cover.
Tighten the new cover bolts to the specified torque.
Front Cover Bolt Torque
N
⋅m (kgf⋅m/lb⋅ft)
24.5
± 2.9 (2.5 ± 0.3 / 18.1 ± 2.2)
MSG MODEL(4WD) 7B-103
TROUBLESHOOTING
Refer to this Section to quickly troubleshooting and repair engine problems.
Each diagnostic chart has three headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into four sub-sections:
1. Abnormal Noise
1) Noise in Neutral
2) Noisy Operation
2. Head Shifting
3. Walking or Jumping Out of Gear
4. Oil Leakage
7B-104 MSG MODEL (4WD)
1. ABNORMAL NOISE
1) NOISE IN NEUTRAL
Checkpoint
Trouble Cause
Countermeasure
Replenish or replace the
engine oil
Insufficient or improper engine
oil
NG
Mainshaft splines
Synchronizer clutch hub
splines
Replace the main shaft and
the synchronizer clutch hub
Replace the thrust washers,
collars, and gears
Replace the gear(s)
Replace the flywheel pilot
Worn splines
Mainshaft and countershaft
thrust play
Worn thrust washers, collars,
and gear thrust faces
Worn or scuffed gear tooth
contact surfaces
Flywheel pilot bearing
Worn flywheel pilot bearing
Bearings (Mainshaft,
countershaft)
Gears (Mainshaft,
countershaft, and reverse idler
gear)
Replace the bearing(s)
Worn or broken bearing(s)
OK
NG
NG
NG
NG
NG
OK
OK
OK
OK
Engine oil
Transmission
Realign the transmission
Transmission misalignment
OK
NG
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