Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1819

MSG MODEL (4WD)  7B-53

Engine Rear Mounting and Crossmember

1. Support the transmission with a transmission jack.

2. Remove No.2 crossmember.

3. Remove  the  engine  rear  mounting  nuts  from  No.3

crossmember 

3

.

4. Remove  the  engine  rear  mounting  bolts  from  the

transmission 

1

.

5. Remove  No.3  crossmember  and  bolts 

3

  from  the  side

frame.

6. Remove the engine rear mounting 

2

.

Starter Motor

Remove the starter motor from the engine real plate.

Transmission with Transfer

1. Remove  the  transmission  nuts  and  bolts  from  the  engine

rear plate.

2. Carefully  pull  the  transmission  with  the  transmission  jack

toward the rear of the vehicle.

3. Operate  the  transmission  jack  to  slowly  lower  the

transmission.

Important Operations - Installation

Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
installation procedure.

Transmission with Transfer

1. Apply a thin coat of molybdenum disulfide grease to the top

gear shaft spline.

2. Place the transmission on a transmission jack.

3. Carefully move the transmission jack and transmission into

position behind the cab.

7B-54  MSG MODEL (4WD)

4. Slowly  raise  the  transsmission  jack  until  the  front  of  the

transmission is aligned with the rear of the engine.

The  slope  of  the  engine  and  the  transmission  must  be  the

same.

5. Align  the  top  gear  shaft  spline  with  the  clutch  driven  plate

internal spline.

6. Install the transmission to the engine.

Tighten  the  transmission  nuts  and  bolt  to  the  specified

torque.

Transmission Nut and Bolt Torque

N

⋅m (kgf⋅m/lb⋅ft)

M10 : 40 

± 10 (4.1 ± 1.0 / 30 ± 7.2)

M12: 78 

± 16 (8.0 ± 1.6 / 58 ± 12)

Starter Motor

Install the starter motor to the engine rear plate.
Starter Motor Bolt Torque

N

⋅m (kgf⋅m/lb⋅ft)

78 

± 16 (8.0 ± 1.6 / 58 ± 12)

Engine Rear Crossmember and Mounting

Member

1. Install the engine  rear  crossmember 

2

  to  the  transmission

1

.

Rear Mounting Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

83.3 

± 4.9 (8.5 ± 0.5 / 61.5 ± 3.6)

2. Install the cross member 

3

 to the mounting rubber 

2

.

Mounting Rubber Nut Torque

N

⋅m(kgf⋅m/lb⋅ft)

41 

± 4.9 (4.2 ± 0.5 / 30 ± 3.6)

3. Install the cross member to the sideframe.

Mounting Member Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

36.8 

± 9.8 (3.8 ± 1.0 / 27.1 ± 7.2)

Slave Cylinder

Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque 

N

⋅m(kgf⋅m/lb⋅ft)

78 

± 16 (8.0 ± 1.6 / 58 ± 12)

MSG MODEL (4WD)  7B-55

Harness Connector

Connect the 4WD switch connector, back up light switch
connector and speedometor sensor connector.

Front Propeller Shaft

1. Connect  the  propeller  shaft  flange  yoke  to  the  matching

flange.

2. Tighten the propeller shaft flange yoke bolt to the specified

torque.

Propeller Shaft Flange Yoke Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

62.7 

± 3.92 (6.4 ± 0.4 / 46.3 ± 2.90)

Note:
If the splined yoke and the front propeller shaft have
accidentally separated, align their setting marks and
recouple them.
Refer to "FRONT PROPELER SHAFT REMOVAL".

Rear Propeller Shaft (Single Shaft Type)

1. Insert  the  splined  yoke 

1

  with  the  propeller  shaft  into  the

transmission main shaft spline 

2

.

2. Install  the  propeller  shaft  flange  yoke 

3

  to  the  drive  pinion

side.

3. Tighten the propeller shaft flange yoke bolt to the specified

torque.

Propeller Shaft Flange Yoke Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

M8 : 35.3 

± 2.94 (3.6 ± 0.3 / 26.0 ± 2.2)

M10 : 62.7 

± 3.9 (6.4 ± 0.4 / 46.3 ± 2.9)

Rear Propeller Shaft (Dual Shaft Type)

1. Place  the  center  bearing 

1

  together  with  the  1st  peopeller

shaft 

2

  and  2nd  propeller  shaft 

7

  on  the  No.4

crossmember 

3

.

2. Insert  the  splined  yoke 

4

  into  the  transmission  main  shaft

spline 

5

.

3. Tighten the center bearing retainer bolts 

6

 to the specified

torque.

Center Bearing Retainer Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

60.8 

± 11.8 (6.2 ± 1.2 / 44.8 ± 8.7)

4. Connect the 2nd propeller shaft 

7

 and drive pinion side 

8

.

Be sure to align the setting marks applied at disassembly.

5. Tighten the coupling bolts to the specified torque.

Propeller Shaft Flange Yoke Bolt

Torque

N

⋅m(kgf⋅m/lb⋅ft)

M10 : 35.3 

± 2.94 (3.6 ± 0.3 / 26.0 ± 2.2)

M12 : 62.7 

± 3.9 (6.4 ± 0.4 / 46.3 ± 2.9)

7B-56  MSG MODEL (4WD)

Exhaust Pipe

1. Install the 2nd exhaust pipe.

Transfer Case Protector

1. Install  the  transfer  case  protector 

1

  to  the  mounting

member 

2

 and the sidemembers 

3

.

2. Tighten  the  transfer  case  protector  bolts  to  the  specified

torque.

Transfer Case Protector Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

36.3 

± 9.8 (3.7 ± 1.0 / 26.8 ± 7.2)

Gear Shift Lever and Transfer Change

Lever

1. Replenish the transmission case and the transfer case with

the specified engine oil.

Transmission and Transfer Case Oil

lit (US gal.)

4.4 (1.16)

2. Install the gear shift lever to the gear control box.

Shift Lever Cover Torque

N

⋅m(kgf⋅m/lb⋅ft)

19.6 

± 1.96 (2.0 ± 0.2 / 14.5 ± 1.5)

3. Install the dust cover.

4. Insert the transfer change lever to the transfer case.

Change Lever Retainer Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

19.6 

± 1.96 (2.0 ± 0.2 / 14.5 ± 1.5)

5. Install the grommet

6. Install  the  front  console  assembly  and  center  console

assembly.

7. Install  the  gear  shift  lever  and  the  transfer  change  lever

knobs.