Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1822

MSG MODEL (4WD)  7B-65

Important Operation

1. Snap Ring
Use a pair of snap ring pliers to remove snap rings.

2. Thrust Ring
Remove the thrust ring.

5. Ball Bearing

6. Cluster 5th Gear
Remover : 5-8840-0013-0

11.Nut and Lock Washer

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

Low/2nd  side  synchronizer  with  the  low  gear,  then  attach

tool to the main shaft and the cluster gear.

Holding fixture : 5-8840-2001-0

(J-29768)

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

when  removing  main  shaft  rear  and  cluster  shaft  reverse

gear lock nut.

Wrench : 5-8840-0353-0

(J-36629)

7B-66  MSG MODEL (4WD)

14.Needle Bearing
Remove the needle bearing (2 piece type).

20.Snap Ring ; Cluster Gear Shaft
Insert the nose of snap ring pliers into the cluster gear side
bearing snap ring hole in the intermediate plate and disengage
the snap ring from the groove by tapping on the front face of
the plate while expanding the cluster gear side bearing snap
ring.

21.Snap Ring ; Main Gear shaft

22.Intermediate Plate
Remove the intermediate plate rearward by expanding the
mainshaft ball bearing snap ring with the snap ring pliers.

MSG MODEL (4WD)  7B-67

  MINOR COMPONENT

TOP/MAIN GEAR SHAFT AND CLUSTER GEAR SHAFT

Disassembly Steps

1. Top gear assembly
2. Needle bearing
3. Snap ring

! 4. Ball bearing

5. 4th blocking ring
6. Snap ring

! 7. 3rd/4th synchronizer assembly

8. 3rd blocking ring
9. 3rd gear

10. Needle bearing
11. Collar
12. Trust Washer

!13. Ball bearing

14. Thrust washer

15. Low gear
16. Needle bearing
17. Collar
18. Low blocking ring

!19. Low/2nd synchronizer assembly

20. 2nd blocking ring
21. 2nd gear
22. Needle bearing
23. Mainshaft

!24. Ball bearing

25. Ball bearing
26. Snap ring
27. Cluster gear shaft

7B-68  MSG MODEL (4WD)

Important Operation

4. Ball Bearing ; Top Gear Shaft

Install the tool under top gear shaft bearing and remove using a
bench press.
Bearing remover : 5-8840-0015-0

(J-22912-01)

7. 3nd/4th Synchronizer Assembly

19.Low/2nd Synchronizer Assembly
Remove synchronizer assembly together with clutch hub, then
disassemble these parts into sleeve, insert, spring and clutch
hub.

13.Ball Bearing ; Main Shaft
Install the tool under 2nd gear and remove using a bench
press.
Bearing remover : 5-8840-0015-0

(J-22912-01)

24.Ball Bearing
Install the tool under cluster gear rear bearing and remove
using a bench press.
Bearing remove : 5-8840-0015-0

(J-22912-01)