Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual - part 1829

MSG MODEL (4WD)  7B-93

Important Operations

1. 4

××××2/4××××4 sleeve

Install the 4

×2/4×4 sleeve the output shaft.

The chamfered side of the sleeve facing the output shaft gear.

4. Thrust Washer
Install the thrust washer to the output shaft.
The oil grooved side of the washer facing the output shaft gear.

5. Ball Bearing
Use a bench press to install the ball bearing to the output shaft.
The snap ring grooved side of the bearing turned to the
speedometer drive gear.

7B-94  MSG MODEL (4WD)

9. Ball bearing
Use a bench press to install the ball bearing to the output shaft.
The shield side of the bearing must be facing to the nut.

10.Nut

1) Install the nut to the output shaft.

2) Tighten the nut to the specified torque.

Nut Hex. : 41 mm (1-5/8 in)

Output Shaft Nut Torque

N

⋅m(kgf⋅m/lb⋅ft)

127.4 

± 9.8 (13 ± 1 / 94.0 ± 7.2)

11.Output Shaft Assembly

1) Install  the  bearing  snap  ring  to  the  transfer  case  snap  ring

groove.

2) Place the output shaft assembly to the transfer case bore.

3) Use a pair of snap ring pliers to expand the snap ring.

4) Move  the  output  shaft  assembly  to  fit  the  snap  ring  to  the

bearing.

16.Thrust Washer
Install the thrust washer to the counter shaft.
The thrust washer oil grooved side must be facing the counter
gear.

17.O-Ring

18.Counter Shaft Assembly

1) Apply new engine oil to the O-ring.

2) Position the counter shaft slot for the thrust washer tang at

twelve o'clock.

3) Make  sure  the  both  of  washer  tangs  positions  at  twelve

o'clock.

4) Install the output shaft assembly to the transfer case bore.

MSG MODEL (4WD)  7B-95

Check to make sure the thrust washer tangs align with the
mating slots properly.

19.High/Low Sleeve
Install the High/Low sleeve to the output shaft.
The chamfered side of the sleeve must be facing the adaptor
case.

21.Distance plate

22.Lock Plate
Semi-tighten the lock plate bolts.
Before tighten the lock plate bolts, must be done the counter
gear clearance adjustment.
Note:
Refer to transfer case assembly installation procedures on
major components in this section.

7B-96  MSG MODEL (4WD)

  MINOR COMPONENT

TRANSFER SIDE CASE ASSEMBLY

Reassembly Steps

! 1. Ball bearing
! 2. Front output shaft gear
! 3. Ball bearing
! 4. Oil seal
! 5. Front output shaft

6. Thrust washer
7. Nut and lock washer
8. Distance piece

! 9. Front output shaft cover
!10. Thrust washer

11. Idler gear
12. Needle bearing

!13. Thrust washer
!14. Idler gear shaft
!15. Dowel pin
!16. High/Low shift arm
!17. High/Low shift rod

18. Interlock pin

!19. 4

×2/4×4 Shift arm and shift block

!20. 4

×2/4×4 Shift rod

!21. Screw plug
!22. Screw plug

23. Detent spring and ball