Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1911

7A4-76 UNIT REPAIR (JR405E)

27ASSY051

•

Install the bearing to the clutch pack.

NOTE:
Apply Vaseline to the bearing.

A07L300002

Total end play measurement

•

Install the bearing race (oil pump) to the clutch pack.

•

Measure the distance (A) between the oil pump

installation surface and the bearing race.

241L300003

•

Measure the distance (B) between the bearing race

installation surface and the machined surface.

•

Calculate the total end play using the following formula.

Total end play = distance (A) – distance (B)

If the measured and calculated end play is outside the

specified range, replace the existing bearing race with a

bearing race of the proper size (thickness).

Total end play = 0.25~0.55 mm (0.0098~0.0217 in)

Available oil pump bearing race thicknesses

1.4 mm (0.055 in)

1.6 mm (0.063 in)

1.8 mm (0.071 in)

2.0 mm (0.079 in)

2.2 mm (0.087 in)

2.4 mm (0.094 in)

UNIT REPAIR (JR405E) 7A4-77

28ASSY058

12.Input shaft

Install the input shaft.

29PUMP02

13.Oil pump assembly

•

Install a new O-ring to the outside of the oil pump.

•

Install the bearing race to the oil pump.

NOTE:
Apply Vaseline to the bearing race.

30ASSY067

•

Apply ATF to the O-ring at the outside of the oil pump.

•

Install the oil pump assembly to the transmission case.

•

Apply sealing agent (TB1215) to the threaded surfaces

of the 8 fixing bolts and tighten to the specified torque.

Torque: 58 N

⋅⋅⋅⋅

m (43 Ib

⋅⋅⋅⋅

ft)

31ASSY068

14.O-ring

Install a new O-ring to the input shaft.

32ASSY116

15.Converter housing

Install the converter housing and tighten the bolts to the

specified torque.

Torque: 53 N

⋅⋅⋅⋅

m (39 Ib

⋅⋅⋅⋅

ft)

7A4-78 UNIT REPAIR (JR405E)

33ASSY075

16.Actuator support

Install the actuator support.

34ASSY077

17.Parking pawl, shaft, spring, and spacer

Install the parking pawl, the shaft, the spring, and the

spacer.

35ASSY082

36ASSY084

37ASSY086

UNIT REPAIR (JR405E) 7A4-79

38OUTPUT25

29ASSY089

18.Output shaft

•

Install a new seal ring to the output shaft assembly.

•

Measure the gap between the seal ring and the ring

groove.

If the gap is outside the specified range, the output shaft

must be replaced.

Seal ring and ring groove gap:

0.10~0.25 mm (0.0039~0.0098 in)

•

Install the bearing to the case.

NOTE:

••••

Apply Vaseline to the bearing (with bearing race).

••••

The black side (bearing race) of the bearing must be

visible.

40ASSY091

•

Push the output shaft into place.

19.Rear extension (2WD) or adapter case (4WD)

•

Use the oil seal installer to install the oil seal to the rear

extension (2WD) or adapter case (4WD).

Oil seal installer:

5-8840-2769-0 (2WD)

5-8840-2770-0 (4WD)

41ASSY096

•

Install the bearing (with bearing race) to the rear

extension (2WD) or adapter case (4WD).

NOTE:

••••

The black side (bearing race) of the bearing must be

visible.

••••

Apply Vaseline to the bearing.