Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1814

MSG MODEL (2WD)  7B-33

19.Top Gear Shaft

20.Ball Bearing
Use a bench press and the installer to install the ball bearing to
the top gear shaft.
The snap ring groove must be facing the front of the
transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)

25.Rear Ball Bearing
Use a bench press and the bearing installer to install the
bearing to the counter gear.
Bearing Installer : 5-8840-0015-0 (J-22912-01)

7B-34  MSG MODEL (2WD)

  REVERSE GEAR AND 5TH GEAR

Reassembly Steps

! 1. Intermediate plate
! 2. Reverse idler shaft

3. Bearing snap ring
4. Bearing snap ring
5. Thrust washer

! 6. Reverse idler gear

7. Thrust washer

! 8. Counter reverse gear lock nut
! 9. Thrust washer

10. Needle bearing collar
11. Needle bearing
12. Reverse gear

!13. Rev.-5th synchronizer assembly
!14. Mainshaft lock nut and washer

15. Needle bearing
16. 5th block ring
17. 5th gear

!18. Thrust washer and lock ball

19. Counter reverse gear
20. Counter 5th gear
21. Counter end ball bearing

!22. Counter reverse gear nut and washer
!23. Thrust washer thrust ring
!24. Thrust ring snap ring

25. Mainshaft end ball bearing
26. Bearing spacer
27. Speedometer drive gear and lock ball
28. Bearing snap ring

MSG MODEL (2WD)  7B-35

Important Operations

1. Intermediate Plate

2. Reverse Idler Shaft

1) Install the reverse idler shaft to the intermediate plate.

2) Tighten the reverse idler shaft bolt to the specified torque.

Idler Shaft Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

18.6 

± 3.9 (1.9 ± 0.4 / 13.7 ± 2.9)

3) Set  the  mainshaft  with  gear  assembly 

1

  and  the  counter

gear assembly 

2

 to the holding fixture 

3

.

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

4) Place the holding fixture (with the mainshaft and the counter

shaft) in a vise.

5) Mesh the 3rd-4th synchronizer to the 3rd gear.

Mesh the 1st-2nd synchronizer to the 1st gear.

6) Install  the  intermediate  plate  to  the  mainshaft  and  the

counter gear ball bearings.

6. Reverse Idler Gear

8. Counter Reverse Gear Lock Nut

1) Apply  the  engine  oil  to  the  idler  shaft  and  the  reverse  gear

inside circumference.

2) Install the reverse gear to the idler shaft.

3) Install a new counter reverse gear lock nut.

Never reinstall the old lock nut.

4) Tighten the reverse gear lock nut to the specified torque.

Lock Nut Torque

N

⋅m (kgf⋅m/lb⋅ft)

107.8 

± 9.8 (11 ± 1.0 / 79.6 ± 7.2)

9. Thrust Washer

1) Apply the engine oil to both sides of the thrust washer.

2) Install the thrust washer to the mainshaft.

The  thrust  washer  oil  groove  must  be  facing  the  reverse

gear side.

7B-36  MSG MODEL (2WD)

13.Rev.-5th Synchronizer Assembly

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

2) Install the synchronizer assembly to the mainshaft.

The  sleeve  heavy  chamfer 

1

  and  the  insert  short  side 

2

must be facing to the rear side of the transmission.

14.Mainshaft Lock Nut and Washer

1) Install a new lock nut and washer to the mainshaft.

Never reinstall the used lock nut and washer.

2) Use  the  lock  nut  wrench  to  tighten  the  lock  nut  to  the

specified torque.

Lock Nut Wrench : 5-8840-0353-0 (J-36629)

Lock Nut Torque

N

⋅m(kgf⋅m/lb⋅ft)

107.8 

± 9.8 (11 ± 1.0 / 79.6 ± 7.2)

22.Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque 

N

⋅m(kgf⋅m/lb⋅ft)

107.8 

± 9.8 (11 ± 1.0 / 79.6 ± 7.2)

18.Thrust Washer and Lock Ball

23.Thrust Washer Thrust Ring

24.Thrust Ring Snap ring

1) Install  the  thrust  washer  with  lock  ball  together  with  the

thrust ring to the mainshaft.

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

3) Use  a  thickness  gauge  to  measure  the  clearance  between

the 5th gear and the thrust washer.

5th Gear and Thrust Washer Clearance

mm(in)

Standard

0.1 - 0.3 (0.004 - 0.012)

If  required,  replace  the  existing  thrust  washer  with  a  new

thrust washer to bring the clearance to specification.