Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1827

MSG MODEL (4WD)  7B-85

16.Mainshaft Snap Ring

1) Select  the  snap  ring  which  will  provide  the  minimun

clearance between the mainshaft and the snap ring.

There are four snap ring sizes available.

The snap rings are numbered to indicate their thickness.

Mainshaft and Snap Ring Clearance

mm(in)

Standard

0-0.05 (0.002)

Snap Ring Availability

mm(in)

Thickness

Identification Number

1.50 (0.059)

1

1.55 (0.061)

2

1.60 (0.063)

3

1.65 (0.065)

4

2) Use a pair of snap ring pliers to install the  snap  ring  to  the

mainshaft.

21.Rear Ball Bearing
Use a bench press and the bearing installer to install the
bearing to the counter gear.
Bearing Installer : 5-8840-0015-0 (J-22912-01)

23.Ball Bearing

24.Top Gear Shaft
Use a bench press and the installer to install the ball bearing to
the top gear shaft.
The snap ring groove must be facing the front of the
transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)

26.Reverse Idler Shaft

1) Install the reverse idler shaft to the intermediate plate.

2) Tighten the reverse idler shaft bolt to the specified torque.

Idler Shaft Bolt Torque

N

⋅m(kgf⋅m/lb⋅ft)

18.6 

± 3.9 (1.9 ± 0.4 / 13.7 ± 2.9)

7B-86  MSG MODEL (4WD)

  MINOR COMPONENT

REV. GEAR AND 5TH GEAR

Reassembly Steps

! 1. Intermediate plate

2. Snap ring
3. Snap ring
4. Rev. idler shaft

! 5. Thrust washer

6. Rev. idler gear

! 7. Thrust washer
! 8. Self lock nut

9. Needle bearing

!10. Rev. gear
!11. Rev./5th synchronizer assembly

!12. Lock washer and nut

13. Needle bearing
14. 5th blocking ring

!15. 5th gear
!16. Thrust washer and ball

17. Thrust ring

!18. Snap ring

19. Cluster Rev. gear
20. Cluster 5th gear

!21. Ball bearing
!22. Washer and lock nut

MSG MODEL (4WD)  7B-87

1. Intermediate Plate
Mesh the cluster gear with the mainshaft assembly and attach
tool to the mainshaft and the counter gear.
Place tool with the mainshaft and counter gear assembled in a
vise, then install the intermediate plate.
Holding fixture : 5-8840-2001-0

(J-29768)

5. Thrust Washer
Check that the flange of the thrust washer is fitted to the
stopper on the inermidiate plate.

Engage the Top/3rd and Low/2nd synchronizers with the 3rd
and Low gears, then attach and tighten the lock nuts to the
specified torque as follows.

7. Thrust Washer

1) Apply the engine oil to both sides of the thrust washer.

2) Install the thrust washer to the mainshaft.

The thrust washer oil groove must be facing the rearward of

the transmission.

8. Self Lock Nut

Torque

N

⋅m(kgf⋅m/lb⋅ft)

107.8 

± 9.8 (11 ± 1 / 79.6 ± 7.2)

Discard the used nut and install new one at reassembly.

7B-88  MSG MODEL (4WD)

10.Reverse Gear
Install the needle bearing and the reverse gear.
Check that there is no dust and waste and apply the engine oil
on the sliding surface.

11.Rev./5th Synchronizer Assembly
When reassembling the synchronizer assembly, the side of the
clutch hub with higher boss must face the heavy chamfer of the
sleeve.
The shorter shoulder side of the insert should be on the same
side.
1 ; Shorter shoulder side

2 ; Heavy chamfering

12.Lock Washer and Nut
Lock the nut with lock washer after tightening it to the specified
torque.
Wrench : 5-8840-0353-0

(J-36629)

Torque

N

⋅m(kgf⋅m/lb⋅ft)

127.4 

± 9.8 (13 ± 1 / 94.0 ± 7.2)

Be absolutely certain to bend the lock washer pawl in two
places.

15.5th Gear
Install the block ring, the split needle bearing and the 5th gear.
Check that there is no dust and waste and apply the engine oil
on the sliding surface.