Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1832

MSG MODEL(4WD)  7B-105

2)  NOISY OPERATION

Checkpoint

Trouble Cause

Countermeasure

Replenish or replace the

engine oil

Insufficient or improper engine

oil

NG

Replace the gear(s)

Replace the gear(s)

Replace the bearing(s)

Gears (Gear whining)

Lack of backlash between

meshing gears

Free running gears seizing on

the thrust face or the inner

face

Bearings (Hissing, thumping

or bumping)

Worn or broken bearing(s)

Gears (Squealing at high

speeds)

Replace the gear(s)

Gears (Growling, humming, or

grinding)

Worn, chipped, or cracked

gear(s)

NG

NG

NG

NG

OK

OK

OK

OK

Engine oil (Metallic rattling)

7B-106  MSG MODEL (4WD)

2.  HARD SHIFTING

Checkpoint

Trouble Cause

Countermeasure

Change lever play

Clutch pedal free play

Repair or replace the

applicable parts and regrease

Readjust the clutch pedal free

play

Worn change lever sliding

portions

Improper clutch pedal free

play

Change lever operation

Repair or regrease the change

lever assembly

Replenish or replace the

engine oil

Hard operating change lever

caused insufficient grease

Insufficient or improper engine

oil

OK

OK

NG

NG

NG

NG

OK

OK

Engine oil

Synchronizer assembly

Shift arm and synchronizer

sleeve

Replace the worn parts

Replace the worn parts

Worn synchronizer parts

Worn shift arm and/or

synchronizer sleeve groove

Mainshaft and countershaft

thrust play

Replace the worn parts

Replace the shift rod and/or

the quadrant box

Worn thrust washer, collar,

and/or gear thrust faces

Worn shift rod and/or sliding

faces

OK

NG

NG

NG

NO

OK

OK

Shift rod and quadrant box

sliding faces, and other parts

MSG MODEL(4WD)  7B-107

3.  WALKING OR JUMPING OUT OF GEAR

Checkpoint

Trouble Cause

Countermeasure

Shift rod and quadrant box

sliding faces

Detent ball

Replace the shift rod and/or

the quadrant box

Replace the detent ball

Worn shift rod and/or sliding

faces

Worn detent ball

Detent spring

Repair or replace the detent

spring

Replace the worn parts

Detent spring weak or broken

Insufficient stroke caused by

sliding position wear and

excessive play

OK

OK

NG

NG

NG

NG

OK

OK

Change lever play

Mainshaft splines

Synchronizer clutch hub

splines

Mainshaft and countershaft

thrust play

Replace the main shaft and

the synchronizer clutch hub

Replace the worn parts

Worn splines

Worn thrust washer, collar,

and/or gear thrust faces

Bearings (Mainshaft,

countershaft, and individual

gears)

Replace the bearing(s)

Replace the worn parts

Worn or broken bearing(s)

Worn shift arm and/or

synchronizer sleeve groove

OK

NG

NG

NG

NO

OK

OK

Shift arm and synchronizer

sleeve

7B-108  MSG MODEL (4WD)

4.  OIL LEAKAGE

Checkpoint

Trouble Cause

Countermeasure

Casting parts (Transmission

case, quadrant box, etc.)

Engine oil

Replace the casting parts

Replace the engine oil

Casting cracked or holed

Improper engine oil

Drain plug and/or filler plug

Tighten the plug(s) and

replenish the oil

Drain the oil to the correct

level

Loose plug(s)

Oil level too high

OK

OK

NG

NG

NG

NG

OK

OK

Oil level

Rear cover oil seal and yoke

seating surface with oil seal

Air breathe

Replace the oil seal and/or the

flange yoke

Install the air breather Replace

the air breather

Worn or scratched oil seal

and/or worn flange yoke

seating surface with oil seal

Air breather not installed Air

breather clogged

Front cover oil seal and top

gear shaft seating surface with

oil seal

Replace the oil seal and/or the

top bear shaft

Replace the gasket(s)

Worn or scratched oil seal

and/or worn top gear shaft

seating surface with oil seal

Defective or improperly

installed gasket(s)

OK

NG

NG

NG

NO

OK

OK

Gaskets