Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1825

MSG MODEL (4WD) 7B-77

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

34.03-34.02

(1.3398-1.3402)

34.10 (1.3425)

Transfer

idler

33.00-33.025

(1.2992-1.3002)

33.10 (1.3031)

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)

TRANSFER IDLER GEAR SHAFT

OUTSIDE DIAMETER

Use a micrometer to measure the idler gear shaft diameter.

mm(in)

Standard

24.99-25.0 (0.9839-0.9843)

7B-78 MSG MODEL (4WD)

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

0-0.19 (0-0.0075)

0.20 (0.0079)

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.

MSG MODEL (4WD) 7B-79

TRANSFER CASE OIL SEAL

Oil Seal Replacement
Oil Seal Removal

Use a screwdriver to pry the oil seal from the transfer case.

Oil Seal Installation

1. Use the oil seal installer to install the oil seal to the transfer

case.

Oil Sesl Installer : 9-8522-1273-0 (J-29769)

2. Apply engine oil to the oil seal lip.

7B-80 MSG MODEL (4WD)

REASSEMBLY

REASSEMBLY OF INTERNAL PARTS (TRANSMISSION)

MAJOR COMPONENT (1)

Reassembly Steps

1. Top & main gear shaft assembly
2. Cluster gear shaft assembly
3. Rev. and 5th gear assembly

4. Shift fork assembly & interlock pin
5. Detent assembly
6. Adapter case and input transfer gear