Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1831

MSG MODEL (4WD)  7B-101

Important Operations

1. Adaptor Case Intermediate Plate with Gear Assembly
Apply recommended liquid gasket or its equivalent to the
adaptor case fitting surfaces.
2. Transfer Case Assembly and Gasket

1) Install the new gasket and the transfer case assembly to the

adaptor case with gear assembly.

Take care not to damage the bearing and the adaptor case

bore.

2) Tighten the transfer case bolts to the specified torque.

Transfer Case Assembly Bolt
Torque

N

⋅m(kgf⋅m/lb⋅ft)

37.2 

± 7.8 (3.8 ± 0.8 / 27.5 ± 5.8)

Transfer Counter Gear Thrust Clearance Adjustment
3) Loosen  the  lock  plate  bolts  that  semi-tightened  on  transfer

case assembling procedures in minor component.

4) Push the counter shaft end toward the adaptor case until it

to stop.

5) Use  the  depth  gauge  or  the  vernier  caliper  to  measure  the

counter shaft end depth 

A

.

6) Select  the  distance  plate  from  the  measured  values  from

the table as next page.

Refference : Counter Shaft Thrust Clearance 

mm(in)

0.1 - 0.35 (0.004 - 0.014)

7B-102  MSG MODEL (4WD)

mm(in)

Thickness of

Distance plate

Measured value (A)

Marking color

3.6 (0.142)

3.7-3.95

(0.146-0.156)

Red

3.8 (0.150)

3.9-4.15

(0.154-0.163)

Orange

4.0 (0.157)

4.1-4.35

(0.161-0.171)

Yellow

4.2 (0.165)

4.3-4.55

(0.169-0.179)

Green

4.3 (0.169)

4.4-4.65

(0.173-0.183)

Blue

3. Transmission Case

1) Apply the engine oil to the transmission case top gear shaft

ball bearing fitting faces.

2) Apply  recommended  liquid  gasket  or  its  equivalent  to  the

transmission case fitting surfaces.

3) Install the transmission case to the intermediate plate.

4. Bearing Snap Ring
Pull the top gear shaft from the transmission case until the ball
bearing snap ring groove protrudes from the transmission case
front cover fitting face.
Use a pair of snap ring pliers to install the snap ring to the ball
bearing.

6. Front Cover with Oil Seal

1) Apply a recommended liquid gasket or equiverent to the bolt

threads.

2) Install the new gasket and the front cover.

Tighten the new cover bolts to the specified torque.

Front Cover Bolt Torque

N

⋅m (kgf⋅m/lb⋅ft)

24.5 

± 2.9 (2.5 ± 0.3 / 18.1 ± 2.2)

MSG MODEL(4WD)  7B-103

TROUBLESHOOTING

Refer to this Section to quickly troubleshooting and repair engine problems.
Each diagnostic chart has three headings arranged from left to right.

(1) Checkpoint   (2) Trouble Cause   (3) Countermeasure

This Section is divided into four sub-sections:

1. Abnormal Noise

1) Noise in Neutral

2) Noisy Operation

2. Head Shifting

3. Walking or Jumping Out of Gear

4. Oil Leakage

7B-104  MSG MODEL (4WD)

1.  ABNORMAL NOISE

1)  NOISE IN NEUTRAL

Checkpoint

Trouble Cause

Countermeasure

Replenish or replace the

engine oil

Insufficient or improper engine

oil

NG

Mainshaft splines

Synchronizer clutch hub

splines

Replace the main shaft and

the synchronizer clutch hub

Replace the thrust washers,

collars, and gears

Replace the gear(s)

Replace the flywheel pilot

Worn splines

Mainshaft and countershaft

thrust play

Worn thrust washers, collars,

and gear thrust faces

Worn or scuffed gear tooth

contact surfaces

Flywheel pilot bearing

Worn flywheel pilot bearing

Bearings (Mainshaft,

countershaft)

Gears (Mainshaft,

countershaft, and reverse idler

gear)

Replace the bearing(s)

Worn or broken bearing(s)

OK

NG

NG

NG

NG

NG

OK

OK

OK

OK

Engine oil

Transmission

Realign the transmission

Transmission misalignment

OK

NG