Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1824

MSG MODEL (4WD)  7B-73

Important Operations

4. 4

××××2/4××××4 Shift Rod

6. High/Low Shift Rods

1) Remove the spring pin from the shift arm.

Spring Pin Remover : 9-8529-2201-0

2) Drive the shift rod toward the output flange.

9. Idler Gear Shaft
Attach a bolt to the idler shaft threads and remove the shaft
from the side case.

Bolt Size

Threads Pitch

8 mm

1.25

Take care not to damage and miss the thrust washers,
bearing, and idler gear.

15.Output Shaft

1) Attach the wrench to the output flange of the shaft.

2) Loosen the output shaft nut.

3) Remove the washers and the shaft.

Wrench : 5-8840-0133-0 (J-8614-01)

17.Output Shaft Front Bearing

18.Output Shaft Rear Bearing
Use the bearing remover to remove the front and the rear
bearing.
Bearing Remover : 5-8523-0010-0 (J-29040)
Grip

: 5-8840-0007-0 (J-8092)

7B-74  MSG MODEL (4WD)

  INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Visual Check

Inspect the following parts for wear, damage or other abnormal
conditions.

Transfer Side Case

1. Front output shaft front bearing

2. Front output shaft rear bearing

3. Idler gear bearing

Transmission and Transfer Case

1. Rear output shaft front bearing

2. Rear output shaft pilot bearing

3. Rear output shaft pilot bearing

4. Rear output gear bearing

5. Transfer input gear bearing

6. Transfer counter gear bearing

Transmission

1. Clutch gear shaft

2. 3rd gear

3. 2nf gear

4. 1st gear

5. Reverse gear

6. Counter gear

7. Counter reverse gear

8. Reverse idle

9. 5th gear

10.5th counter gear

MSG MODEL (4WD)  7B-75

SHIFT ARM THICKNESS

Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness

mm(in)

Standard

Limit

1st-2nd

9.65-9.85 (0.380-0.388)

9.0 (0.354)

3rd-4th

6.95-7.2 (0.273-0.283)

6.5 (0.256)

Rev.-5th

6.8-6.9 (0.268-0.272)

6.3 (0.248)

Transfer

6.7-6.8 (0.264-0.268)

6.0 (0.236)

DETENT SPRING FREE LENGTH

Use a vernier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the detent
spring must be replaced.
Detent spring Free Length

mm(in)

Standard

limit

Transmission

25.6 (1.01)

23.6 (0.93)

Transfer

43.0 (1.69)

41.0 (1.61)

DETENT SPRING TENSION

Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension

N (kg/lb)

Compressed

Height mm(in)

Standard

Transmission

22.1 (0.870)

61.7-65.7

(6.3-6.7/13.7-14.8)

Transfer

36.1 (1.421)

19.84-24.25

(9-11)

7B-76  MSG MODEL (4WD)

BLOCK RING AND DOG TEETH

CLEARANCE

Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance

mm(in)

Standard

Limit

1st, 2nd

2.0 (0.078)

1.3 (0.051)

3rd, 4th, 5th

1.5 (0.059)

0.8 (0.031)

BLOCK RING AND INSERT CLEARANCE

Use a thickness gauge to measure the clearance between the
block ring and the inset.
If the measured value exceeds the specified limit, the block
ring and/or the insert must be replaced.
Block Ring and Insert Clearance

mm(in)

Standard

Limit

1st, 2nd

3.46-3.74 (0.136-0.147)

3rd, 4th, 5th

3.51-3.79 (0.138-0.149)

4.0 (0.157)

CLUTCH HUB AND INSERT CLEARANCE

Use a thickness gauge to measure the clearance between the
clutch hub and the insert
If the measured value exceeds the specified limit, the clutch
hub and/or the insert must be replaced.
Clutch Hub and Insert Clearance 

mm(in)

Standard

Limit

0.01-0.19 (0.0004-0.0075)

0.3 (0.012)

MAINSHAFT RUN-OUT

Use a dial indicator to measure the mainshaft central portion
run-out.
If the measured mainshaft run-out exceeds the specified limit,
the mainshaft must be replaced.
Mainshaft Run-Out

mm(in)

Limit

Less than 0.03 (0.0012)