Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1821

MSG MODEL (4WD)  7B-61

  DISASSEMBLY OF INTERNAL PARTS (TRANSFER)

MAJOR COMPONENT (2)

1

2

Disassembly Steps

1. Transfer case assembly
2. Transfer side case assembly

7B-62  MSG MODEL (4WD)

  MINOR COMPONENT

ADAPTOR CASE, INTERMEDIATE PLATE WITH GEAR ASSEMBLY

Disassembly Steps

1. Oil guide
2. Spacer

! 3. Thrust input hub nut

4. Thrust input hub
5. High-Low shift sleeve
6. Thrust input gear
7. Needle bearing
8. Thrust input gear collar
9. Ball bearing

10. Snap ring
11. Snap ring
12. Adaptor case

13. Detent spring plate and gasket.
14. Detent spring

!15. Detent ball

16. Rev.-5th shift rod
17. Rev.-5th shift arm
18. 1st-2nd shift rod

!19. 3rd-4th shift rod
!20. 3rd-4th shift arm
!21. 1st-2nd shift arm

22. Interlock pin
23. Intermediate plate with gear assembly

MSG MODEL (4WD)  7B-63

Important Operations

5-8511-0110-0

3. Thrust Input Hub Nut

(1) Engage  Top/3rd  side  synchronizer  with  the  third  gear  and

Low/2nd side synchronizer with the low gear.

(2) This  operation  is  necessary  to  prevent  turning  of  the  shaft

when removing main shaft rear.

Wrench : 5-8511-0110-0

(J-29041)

15.Detent Ball
Use a magnetic hand to remove the detent balls from the
intermediate plate.
Take care not to lose the detent balls.

19.3rd-4th Shift Rod

20.3rd-4th Shift Arm

21.1st-2nd Shift Arm

1) Hold a round bar against the shift arm end.

This will prevent damage to other components.

2) Use a spring pin remover to remove the shift arm spring pin

from the shift arm and the shift rod.

Spring Pin Remover : 9-8529-2201-0

Discard the used spring pin.

3) Move the 3rd-4th shift rod forward.

Take care not to lose the interlock pins.

7B-64  MSG MODEL (4WD)

  MINOR COMPONENT

REV. GEAR AND 5TH GEAR

Disassembly Steps

! 1. Snap ring
! 2. Thrust ring

3. Thrust washer and lock ball
4. Self lock nut and washer

! 5. Ball bearing
! 6. Cluster 5th gear

7. Cluster Rev. gear
8. 5th gear
9. Needle bearing

10. 5th blocking ring

!11. Nut and lock washer

12. Rev./5th synchronizer assembly

13. Rev. gear

!14. Needle bearing

15. Lock nut
16. Thrust washer
17. Rev. idler gear
18. Thrust washer
19. Rev. idler shaft

!20. Snap ring
!21. Snap ring
!22. Intermediate plate