Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1830

MSG MODEL (4WD)  7B-97

Important Operations

1. Ball Bearing
Use the bearing installer to install the bearing to the side case.
Bearing Installer  : 5-8523-0010-0 (J-29040)
Grip

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

2. Front Output Shaft Gear
Install the output shaft gear to the case.
The gear that the smooth side must be facing the output
flange.

3. Ball Bearing
Use the bearing installer to install the bearing to the case.
Bearing Installer  : 5-8523-0010-0 (J-29040)
Grip

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

4. Oil Seal
Use the oil seal installer to install the oil seal to the case.
Bearing Installer : 5-8523-0010-0 (J-29040)
Grip

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

5. Front Output Shaft

1) Install the output shaft to the bearings.

2) Use the wrench to tighten the nut to the specified torque.

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

Output shaft Nut Torque

N

⋅m(kgf⋅m/lb⋅ft)

147.1 

± 9.8 (15 ± 1 / 108.5 ± 7.2)

7B-98  MSG MODEL (4WD)

9. Front Output Shaft cover
Tighten the cover bolt to the specified torque.
Cover Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

24.5 

± 2.9 (2.8 ± 0.3 / 20.3 ± 2.2)

10.,13. Thrust Washer

1) Apply a grease to the thrust washers.

2) Attach the thrust washer tang to the case slot.

The oil grooved side must be facing the idler gear.

14.Idler Gear Shaft

1) Apply engine oil to the O-ring.

2) Attach the O-ring to the idler gear shaft.

3) Align the dowel pin slot of the shaft end with the case hole.

4) Install the gear shaft to the case bore.

15.Dowel Pin

1) Install the dowel pin fully to the case dowel bore.

2) Check the dowel pin end projection using the depth gauge.

Dowel Pin Projection

mm (in)

Standard

9 - 11 (0.35-0.43)

16.High/Low Shift Arm

17.High/Low Shift Rod

1) Set  the  spring  pin  to  the  High/Low  shift  arm,  securely  as

shown in the illustration.

MSG MODEL (4WD)  7B-99

2) Install the High/Low shift rod to the case bore.

3) Set the shift arm to the shift rod.

4) Install the spring pin into the shift arm through the shift rod.

Do not install a used spring pin.

19.4

××××2/4××××4 Shift Arm and Shift Block

Place the 4

×2 shift arm and the shift block to connect them with

the release spring.

20.4

××××2/4××××4 Shift Rod

1) Insert  the  interlock  pin,  the  shift  rod  detent  ball  and  the

detent spring in the case.

2) Insert and secure the shift arm, the shift block and the shift

rod in position with the spring pin.

21., 22. Screw Plug

1) Install the screw plug to the case.

2) Tighten the screw plug to the specified torque.

Screw Plug Torque

N

⋅m(kgf⋅m/lb⋅ft)

49.0 

± 9.8 (5.0 ± 1.0 / 36.2 ± 7.2)

7B-100  MSG MODEL (4WD)

  MAJOR COMPONENTS

Reassembly Steps

! 1. Adaptor case intermediate plate with

gear assembly

! 2. Transfer case assembly and gasket
! 3. Transmission case
! 4. Bearing snap ring

5. Counter gear snap ring

! 6. Front cover with oil seal

7. Transfer side case assembly
8. Speedometer driven gear
9. Gear contorl box assembly

10. Speedimeter senor
11. Clutch shift fork
12. Cluch shift block and release bearing