Isuzu D-Max 2007-2012 factory workshop and repair manual download

- Safety and prerequisites
- Wear safety glasses, gloves, and sturdy clothing; work on a flat surface with wheel chocks to prevent movement.
- Have a factory service manual or exact workshop instructions for your D-Max year/model and transmission type; torque specs, bolt patterns, and certain clearances vary by year and transmission and are required.
- If you only have "basic tools" be aware: transmission pump replacement usually requires removing or partially disassembling the automatic transmission. This is an advanced job. If you don’t have a transmission jack, engine support, or a clean, level workspace, plan to get professional help.
- Drain transmission fluid carefully into a proper container and dispose of used fluid per local regulations.

- Tools — each tool named, what it does, and how to use it
- Floor jack
- Lifts the vehicle; use with jack points specified in the manual.
- Place jack under a rated lift point, pump handle to raise; always set jack stands before going under the truck.
- Jack stands
- Support the vehicle safely once lifted; never rely on the jack alone.
- Position under the recommended frame points and lower the vehicle onto stands, ensuring stability.
- Wheel chocks
- Blocks wheels to stop rolling; place behind and in front of wheels left on the ground.
- Socket set (metric), ratchet, and extensions
- Removes bolts and nuts of various sizes (engine/transmission bolts, pan bolts).
- Use the correct socket size, pull the ratchet in controlled strokes; extensions give reach into tight spaces.
- Breaker bar
- Provides leverage for tight/long‑torqued bolts.
- Fit the correct socket and apply steady force; avoid jerking to prevent rounding fasteners.
- Torque wrench (click‑type, correct range)
- Tightens bolts to manufacturer torque specs (critical for transmission bolts/seals).
- Set the specified torque, tighten smoothly until the wrench clicks; re‑check after initial run.
- Transmission jack or a very sturdy floor jack with adapter
- Supports and lowers transmission safely during removal/installation.
- Center the transmission on the jack, secure with straps if available, and lower/raise slowly.
- Engine support bar or engine hoist (if required)
- Holds the engine if front‑mounted engine/gearbox support is removed.
- Follow tool instructions to take load off mounts before removing transmission mounts.
- Drain pan and fluid pump/siphon
- Catches old fluid and helps refill without spills.
- Position drain pan under pan/lines; use pump to add fluid back via dipstick tube or fill port.
- Pry bars / transmission case spreader (careful)
- Separate transmission halves or loosen stuck parts; use flat, controlled leverage only to avoid damage.
- Pick set and seal puller
- Remove O‑rings, seals, and small components.
- Work behind seal lip and pull gently to avoid scratching bores.
- Snap‑ring pliers
- Remove and install circlips inside the transmission.
- Match internal/external plier type to the ring and keep tension controlled.
- Seal driver set or appropriate sized sockets
- Install new seals evenly without damaging them.
- Place seal squarely and tap gently with a hammer until seated flush.
- Bearing puller / slide hammer / hydraulic press (may be required)
- Remove or install bearings and pressed parts on pump assembly.
- Use proper adapters and pull straight to avoid damaging housings; a press is preferred for precise seating.
- Impact wrench (optional but helpful)
- Speeds removal of stubborn bolts; use with care—finish final torque with a torque wrench.
- Clean rags, parts cleaner/degreaser, and a container for small parts/bolts
- Clean mating surfaces and keep hardware organized.
- Use lint‑free rags and solvent; avoid contamination of internal parts.
- Transmission fluid & filter (new)
- Required replacement after pump work; use correct spec fluid for your transmission.
- Refill to the level specified in the manual; use filter and pan gasket if removed.
- Replacement pump (OEM or reman), seals, gaskets, O‑rings, and any bearings or snap rings specified
- The pump itself and associated seals wear; replace pump drive seal, O‑rings, and pan gasket as a minimum.
- Buy the correct pump for your D‑Max year and transmission model—match part numbers.

- Why extra/special tools are required
- Transmission jack and engine support: transmission is heavy and must be supported safely; standard jacks are unstable for this.
- Torque wrench: transmission fasteners and seal clamping require accurate torque to prevent leaks and damage.
- Bearing press/slide hammer: pump components may be pressed fit; using wrong removal methods will damage housings.
- Snap‑ring pliers and seal drivers: internal retentions and seals must be handled with special tools to avoid distortion and leaks.
- Clean workspace and parts cleaning gear: contamination inside the transmission can destroy the unit quickly.

- Parts you will likely need and why
- Transmission pump (hydraulic/oil pump)
- Worn or damaged pump causes low line pressure, slipping, or failure to engage gears; replace if worn, noisy, or leaking internally.
- Pump gasket/seals and O‑rings
- Seals degrade; replacing them prevents external leaks and internal fluid loss.
- Torque converter pump seal (drive seal) and output shaft seals
- Prevent fluid leakage between converter and pump/shaft; often replaced during pump service.
- Transmission filter and pan gasket
- Filter catches metal debris from a failing pump; replace to avoid recontamination. Pan gasket prevents external leaks.
- Bearings and thrust washers (if worn)
- Pump mechanical wear often involves bearings; inspect and replace to restore pump clearance and pressure.
- Fasteners (if damaged or torque‑to‑yield)
- Some bolts may be single‑use or corroded; replace to ensure proper clamping.
- Transmission fluid (correct spec, quantity per manual)
- Fresh fluid required after work; degraded fluid reduces pump lubrication and causes further wear.
- Remanufactured vs OEM pump
- OEM matches original specifications; remanufactured can be cheaper but verify quality and warranty.

- Procedure overview (high‑level, stepwise actions; consult manual for torque and model‑specific steps)
- Prepare vehicle: park on level ground, chock wheels, disconnect battery negative.
- Lift and support vehicle: use floor jack and jack stands on specified points; ensure safe access to transmission and oil pan.
- Drain transmission fluid: remove drain plug or loosen pan bolts; catch fluid and remove pan if required for access.
- Remove ancillaries and connectors: disconnect shift linkage, electrical connectors, cooler lines (cap lines to avoid fluid loss), starter if blocking access, and any crossmembers per the manual.
- Support engine if engine mounts will be loosened or removed.
- Support and remove transmission: use transmission jack, remove mount bolts, unbolt bellhousing bolts in the correct sequence, and carefully lower transmission away from engine.
- Remove torque converter and transmission oil pump area cover: with the transmission off the truck or opened, unbolt pump cover or remove pump housing as directed by your manual.
- Inspect pump and internals: check gears/rotor, wear patterns, bearings, thrust surfaces, and mating faces. Look for metal particles in pan/filter.
- Remove pump assembly: take out pump gears/rotors, seals and snap rings. Use puller/press for pressed components. Keep parts in order and note orientation.
- Clean mating surfaces thoroughly: remove old gasket material and debris; use solvent and lint‑free rags.
- Install new pump and seals: press bearings and gears as required, install new seals with seal driver, replace snap rings, and assemble per orientation in manual.
- Reassemble transmission: reinstall pump cover, torque bolts to spec, reinstall torque converter (lubricate), align and mate transmission to engine, and torque bellhousing bolts.
- Reconnect lines and ancillaries: reinstall crossmembers, linkage, cooler lines, electrical connectors, starter, etc.
- Refill with correct transmission fluid: use the specified type and quantity; run engine to warm up and check fluid level at operating temperature per manual procedures.
- Test drive and recheck: short low‑speed drive, then check for leaks and re‑verify fluid level. Monitor shifting behavior; if problems persist, further inspection required.

- How to use some tools in the most critical steps (practical tips)
- Using the transmission jack
- Center the unit under the transmission bellhousing, strap the case to the jack saddle, and raise incrementally while verifying clearance from frame; lower very slowly and evenly.
- Using a torque wrench
- Clean the bolt threads, hand‑start bolts to avoid cross‑threading, tighten in the specified sequence, and apply torque smoothly until the wrench clicks; re‑check after initial run if manual suggests.
- Removing seals with a seal puller/pick
- Work from behind the seal lip, be careful not to scratch the bore; a damaged bore requires rework or replacement and will leak.
- Pressing bearings/gears
- Use a press or correctly sized sockets to push evenly; do not strike bearings with a hammer directly.

- Inspection checkpoints (what to look for so you know pump replacement was necessary)
- Low or inconsistent line pressure on a pressure gauge (requires instrument).
- Shifting problems: slipping, delayed engagement, no drive.
- Very noisy pump area or grinding metallic contamination in filter/pan.
- External leaks originating at pump seals or transmission case.
- Excessive metal in the pan/filter.

- Post‑work checks and maintenance
- Verify proper fluid level at operating temperature and correct fill method for your model (dipstick or fill plug).
- Check for leaks for the first 50–100 km and re‑torque accessible bolts per manual if recommended.
- Change fluid/filter at recommended intervals to protect the new pump.

- If you are a complete beginner — final practical advice (direct)
- This repair is complex and requires heavy, precise lifting and special tools; if you don’t have a transmission jack, engine support, seal drivers, and a press or access to a clean workspace, take the vehicle to a transmission shop.
- If you proceed DIY, get the exact factory service manual for your D‑Max year/transmission model and follow torque specs and sequences exactly.

- Waste and environmental handling
- Collect and store used fluid in a sealed container and take to an approved recycling center; don’t pour on ground or down drains.

- Parts sourcing tip
- Use the vehicle VIN to confirm the transmission model and order OEM or reputable reman parts; bring the old pump and seals to a parts store if uncertain.

- Common replacement part reference (examples)
- OEM transmission pump assembly (specific to D‑Max transmission model)
- Pump housing gasket, internal O‑rings, torque converter pump seal, output shaft seal
- Transmission filter and pan gasket
- Bearings/thrust washers if inspection shows wear
- Correct ATF fluid per Isuzu specification

- Final note
- Follow the factory procedures exactly for disassembly/reassembly sequences and torque specs. If any step or tool is unfamiliar, stop and consult a professional to avoid costly damage.
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