Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1813

MSG MODEL (2WD)  7B-29

  REASSEMBLY

MAJOR COMPONENT

INTERNAL PARTS

Reassembly steps

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

4. Shift fork assembly & interlock pin
5. Detent assembly

7B-30  MSG MODEL (2WD)

  MINOR COMPONENTS

TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR

Reassembly Steps

1. Mainshaft

! 2. Needle bearing
! 3. 2nd gear

4. 2nd block ring

! 5. 1st-2nd synchronizer assembly

6. 1st block ring

! 7. Needle bearing collar
! 8. Needle bearing
! 9. 1st gear
!10. 1st gear thrust washer
!11. Mainshaft ball bearing
!12. Needle bearing
!13. 3rd gear

14. 3rd block ring

!15. 3rd-4th synchronizer assembly
!16. Mainshaft snap ring

17. Needle bearing
18. 4th block ring

!19. Top gear shaft
!20. Ball bearing

21. Top gear shaft snap ring
22. Counter gear
23. Front ball bearing
24. Bearing snap ring

!25. Rear ball bearing

MSG MODEL (2WD)  7B-31

Important Operations

2. Needle Bearing

3. 2nd Gear

1) Apply the engine oil to the 2nd needle bearing and the 2nd

gear.

2) Install  the  needle  bearing  and  the  2nd  gear  to  the

mainshaft.

The dog teeth of the 2nd gear must be facing the rear side

of the transmission.

5. 1st-2nd Synchronizer Assembly

1) Apply the engine oil to the clutch hub spline.

2) Install the synchronizer assembly to the mainshaft.

The  outside  sleeve  heavy  chamfering  must  be  facing  the

rear of the transmission.

1

Chamfer Angle = 30

°

2

Chamfer Angle = 45

°

7. Needle Bearing Collar
Use a bench press and the collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)

8. Needle Bearing

9. 1st Gear

1) Apply  the  engine  oil  to  the  1st  needle  bearing  and  the  1st

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 1st gear must be facing the front side

of the transmission.

10.1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the 1st gear side.

7B-32  MSG MODEL (2WD)

11.Mainshaft Ball Bearing

1) Apply the engine oil to the ball bearing inside circumference.

2) Use  a  bench  press  and  the  bearing  installer  to  install  the

bearing.

The bearing snap ring groove must be facing the front of the

transmission.

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

12.Needle Bearing

13.3rd Gear

1) Apply  the  engine  oil  to  the  3rd  needle  bearing  and  the  3rd

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 3rd gear must, be facing the front side

of the transmission.

15.3rd-4th Synchronizer Assembly

1) Apply  the  recommended  lubricating  oil  to  the  clutch  hub

spline.

2) Install the synchronizer assembly to the mainshaft.

The  sleeve  light  chamfering 

1

  and  the  clutch  hub  heavy

boss 

2

 must be facing the rear of the transmission.

16.Mainshaft Snap Ring

1) Select  the  snap  ring  which  will  provide  the  minimum

clearance between the mainshaft and the snap ring.

There are four snap ring sizes available.

The snap rings are numbered to indicate their thickness.

Mainshaft and Snap Ring Clearance

mm(in)

Standard

0 - 0.05 (0.002)

Snap Ring Availability

mm(in)

Thickness

Identification Number

1.50 (0.059)

1

1.55 (0.061)

2

1.60 (0.063)

3

1.65 (0.065)

4

2) Use a pair of snap ring pliers to install the  snap  ring  to  the

mainshaft.