Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1826

MSG MODEL (4WD)  7B-81

  REASSEMBLY OF INTERNAL PARTS (TRANSFER)

MAJOR COMPONENT (2)

Reassembly Steps

1. Transfer case assembly
2. Transfer side case assembly

7B-82  MSG MODEL (4WD)

  MINOR COMPONENTS

INTERMEDIATE PLATE, TOP GEAR SHAFT, MAINSHAFT GEAR WITH COUNTER GEAR

Reassembly Steps

1. Mainshaft

! 2. Needle bearing
! 3. 2nd gear

4. 2nd block ring

! 5. 1st-2nd synchronizer assembly

6. 1st block ring

! 7. Needle bearing collar
! 8. Needle bearing
! 9. 1st gear
!10. 1st gear thrust washer
!11. Mainshafr ball bearing
!12. Needle bearing
!13. 3rd gear

14. 3rd block ring

!15. 3rd-4th synchronizer assembly

!16. Mainshaft snap ring

17. 4th block ring
18. Counter gear
19. Front ball bearing
20. Bearing snap ring

!21  Rear ball bearing

22. Needle bearing

!23. Ball bearing
!24. Top gear shaft

25. Top gear shaft snap ring

!26. Reverse idler shaft

27. Bearing snap ring
28. Bearing snap ring

MSG MODEL (4WD)  7B-83

Important Operations

2. Needle Bearing

3. 2nd Gear

1) Apply the engine oil to the 2nd needle bearing and the 2nd

gear.

2) Install the needle bearing and the 2nd gear to the mainshaft.

The dog teeth of the 2nd gear must be facing the rear side

of the transmission.

5. 1st-2nd synchronizer assembly

(1) The side of the clutch hub with the 

2

 oil groove should be

turned to the 2nd gear side.

1

: Oil groove

2

: Oil groove Forward

(2) Check  that  the  inserts  are  fitted  properly  into  the  insert

grooves in the blocker ring and that the insert spring is fitted

to the insert keys as shown in this figure.

Then check that the clutch hub and sleeve slide smoothly.

(3) Install the synchronizer assembly on the shaft, so that face

of  sleeve  with  light  chamfer  on  the  outer  edge  is  turned  to

the front of transmission.

3

 ; Insert key

4

 ; Insert spring

5

 ; Clutch hub

7. Needle Bearing Collar
Use a bench press and the collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)

7B-84  MSG MODEL (4WD)

8. Needle Bearing

9. 1st Gear

1) Apply  the  engine  oil  to  the  1st  needle  bearing  and  the  1st

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 1st gear must be facing the front side

of the transmission.

10.1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the front of the
transmission.

11.Mainshaft Ball Bearing

1) Apply the engine oil to the ball bearing inside circumference.

2) Use  a  bench  press  and  the  bearing  installer  to  install  the

bearing.

The bearing snap ring groove must be facing the front of the

transmission.

Bearing Installer : 5-8840-0015-0 (J-22912-01)

12.Needle Bearing

13.3rd Gear

1) Apply  the  engine  oil  to  the  3rd  needle  bearing  and  the  3rd

gear.

2) Install the needle bearing and the gear to the mainshaft.

The dog teeth of the 3rd gear must be facing the front side of

the transmission.

15.3rd-4th Synchronizer Assembly

1) Apply  the  recommended  lubricating  oil  to  the  clutch  hub

spoine.

2) Install the synchronizer assembly to the mainshaft.

The  sleeve  light  chamfering 

1

  and  the  clutch  hub  heavy

boss 

2

 must be facing the rear of the transmission.