Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1811

MSG MODEL (2WD)  7B-21

Important Operations

9.Counter End Ball Bearing

10.Counter 5th Gear
Use the gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)

15. Mainshaft Lock Nut and Washer

1) Engage the 3rd - 4th synchronizer with the 3rd gear.

2) Engage the 1st - 2nd synchronizer with the 1st gear.

3) Attach  the  holding  fixture  to  the  mainshaft  and  the

countergear.

Holding Fixture : 5-8840-2001-0 (J-29768)

4) Use the lock nut wrench to remove the lock nut.

Lock Nut Wrench: 5-8840-0350-0 (J-36629)

16.Rev. - 5th Synchronizer Assembly

1) Remove the synchronizer assembly as a set.

2) Disassemble the synchronizer assembly.

1

Springs

2

Sleeve

3

Clutch Hub

4

Inserts

26.Bearing Snap Ring

1) Insert  the  snap  ring  pliers 

1

  into  the  counter  gear  bearing

snap ring hole 

2

.

The snap ring hole is in the intermediate plate 

3

.

2) Use  the  snap  ring  pliers  to  force  open  the  counter  gear

bearing snap ring.

Tap on the front of the intermediate plate.

The ball bearing snap ring will come free.

7B-22  MSG MODEL (2WD)

27.Bearing Snap Ring

28.Intermediate Plate

1) Insert  the  snap  ring  pliers  into  the  mainshaft  bearing  snap

ring hole.

The snap ring hole is in the intermediate plate 

1

.

2) Use  the  snap  ring  pliers 

2

  to  force  open  the  mainshaft

bearing snap ring 

3

.

Hold the snap ring open with the pliers.

3) Push  the  intermediate  plate  toward  the  rear  of  the

transmission to remove it.

The ball bearing snap ring will come free.

MSG MODEL (2WD)  7B-23

  TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR

Disassembly Steps

! 1. Top shaft snap ring
! 2. Top gear shaft
! 3. Ball bearing

4. Needle bearing
5. 4th block ring
6. Mainshaft snap ring

! 7. 3rd - 4th synchronizer assembly

8. 3rd block ring
9. 3rd gear

10. Needle bearing

!11. Mainshaft ball bearing

12. 1st gear thrust washer
13. 1st gear

14. Needle bearing collar
15. Needle bearing
16. 1st block ring

!17. 1st - 2nd synchronizer assembly

18. 2nd block ring
19. 2nd gear
20. Needle bearing
21. Mainshaft

!22. Rear ball bearing

23. Bearing snap ring

!24. Front ball bearing

25. Counter gear

7B-24  MSG MODEL (2WD)

Important Operations

1. Top Gear Shaft Snap Ring

2. Top Gear Shaft

3. Ball Bearing

1) Use a pair of snap ring pliers to remove the snap ring.

2) Use a bench press and the bearing remover to remove the

ball bearing.

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

7. 3rd - 4th Synchronizer Assembly

1) Remove the synchronizer assembly as a set.

2) Disassembly the synchronizer assembly.

1

Springs

2

Sleeve

3

Clutch Hub

4

Inserts

11.Mainshaft Ball Bearing
Use a bench press and the bearing remover to remove the ball
bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)

17.1st - 2nd Synchronizer Assembly

1) Remove the synchronizer assembly as a set.

2) Disassembly the synchronizer assembly.

1

Springs

2

Sleeve

3

Clutch Hub

4

Inserts

22.Rear Ball Bearing

24.Front Ball Bearing
Use a bench press and the bearing remover to remove the ball
bearing.
Bearing Removar : 5-8840-0015-0 (J-22912-01)