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.