The Isuzu D-Max is a pickup truck built by automaker Isuzu since 2002.
It shares the exact same system with some General Motors (GM) mid-size
trucks in the United States as the Chevrolet Colorado, GMC Canyon and
Isuzu i-Series. The Chevrolet Colorado name is additionally used to a
rebadged variation of the D-Max in the Middle East and Thailand,
although not identical to the American version. The original D-Max is
sold alongside the Chevrolet Colorado in the Thai market in which they
are both built. In Australasia between 2003 and 2008, the D-Max was
marketed as the Holden Rodeo, but has since been relaunched as the
Holden Colorado. The Isuzu D-Max itself was additionally introduced in
Australia during 2008, selling alongside the Holden offering. in the
United Kingdom, the D-Max is offered there as the Isuzu Rodeo.
Julie Beamer, director of GM Chile announced on March
5, 2008 to their workers of the only remaining automobile factory in
Chile would close on July 31. To that day, the only product currently on
production on that factory was the Chevrolet D-Max. The information
came little after Hugo reduced the import quota for cars in
Venezuela, the main export market of Chilean-made Chevrolet D-Max, but
GM Chile said on its official statement that the reason behind the end
of manufacturing in Arica were the lack of favourable conditions for
vehicle production in Chile, and the stiff competition from many other
carmakers and countries on Chile's car market.
The Thai-market Colorado is smaller than the North
United states model of the exact same name and almost unrelated. In
belated January 2006, Chevrolet introduced a G-80 differential lock
system as elective for most Colorado trim levels. This feature is not
available on the D-Max. The Thai-market Colorado received a minor
redesign in late 2007.
Late first quarter of 2008, Chevrolet additionally
introduced Colorado 4x2 2.5 with diesel dual fuel system via CNG tank.
Switchable between diesel (65) and compressed natural gas (35) as the
separated aspect (65:35); moreover additionally can use diesel purely as
well. Biodiesel B5 is also acceptable. Location of tank is on the bed
behind cab. Available for 2 cabstyles.
In March 2011, Chevrolet revealed the prototype
version of all-new Colorado at Bangkok Motor Show, not related anymore
to D-Max, shown as Extended cab with rear access system, and some of
high-tech stuff, In June 2011, Chevrolet revealed crew cab in adventure
concept at Buenos Aires, Argentina (this car also shown at Frankfurt
Auto Show on September, 2011), and in July 2011, a Holden version of
crew-cab version concept car got its premier at Australian International
Motor Show, but the interior of this vehicle looked like manufacturing
models any more than 2 concepts before.
In September 9, 2011, General Motors (Thailand) are
opening the diesel engine manufacture plant, to make the "Duramax"
engine, as the VM Motori rebadge engine (same as old 2-liter diesel
Captiva) with 2.5 or 2.8-liter, manual and 2WD, automatic or 4WD. New
2012 Isuzu D-MAX Pickup Truck is actually the Chevy Colorado's Asian
Twin.
Isuzu has long abandoned the U.S. Passenger and truck
marketplace but it continues to have strong ties with General Motors,
which was once its primary stockholder. In 2011, the Japanese automaker
revealed its all-new D-MAX pickup truck, which was designed in
cooperation with GM and is a sibling model to the 2012 Chevrolet
Colorado. Albeit on separate occasions, both pickup truck models were
presented in Thailand. On the outside, the new 2012 D-MAX qualities
different front and back end styling treatments as well as bespoke trim
parts, while inside, the changes over the Colorado are limited to the
color options and the instrument panel. The body-on-frame Isuzu D-MAX
launches in Thailand with three turbodiesel engines, including a pair of
2.5-liter units producing 115HP and 136HP, and a larger 3.0-liter
powerplant with 177-horses.
Isuzu D-Max 2007-2012 Factory Service Workshop Manual
Quick summary (so you know what’s coming): the drivetrain takes power from the engine and delivers it to the wheels. I’ll explain how it works, every major component you’ll encounter on an Isuzu D‑Max (2WD and 4WD variants), what commonly fails, how to diagnose those failures, and how to approach repairs as a beginner mechanic — including the tools, safety steps, and general procedures. I’ll avoid model-year-specific torque numbers and exact fluid specs — always use the Isuzu factory service manual or the cap/label for those.
READ THIS FIRST: drivetrain work involves heavy parts, jacking, compressed springs, and hot fluids. Use proper jack stands, wheel chocks, gloves, eye protection, and follow the factory manual for torque specs and special procedures. If anything feels beyond your tools or confidence, get a pro.
1) Drivetrain theory — the big picture (analogy)
- Analogy: think of the drivetrain as a power delivery pipeline. The engine is the powerplant; the gearbox is the set of gears that selects the speed/torque; the transfer case (on 4WD) is a splitter that sends power front and rear; the driveshaft(s) are the long pipes that carry rotational force; differentials are the gearbox at each axle that let wheels turn at different speeds in turns; the axles and wheel bearings are the final delivery hardware that turn the wheel.
- Why repairs are needed: wear, contamination, lack of lubrication, impact damage, failing seals, or worn joints cause noise, vibration, leaks, slipping, loss of drive, and unsafe handling. Diagnosing early and fixing seals, bearings, joints, or fluids prevents bigger failures (e.g., a broken driveshaft can damage the vehicle or cause loss of control).
2) Components, function, and what can go wrong (detailed)
I’ll list each component, describe what it does, how it fails, and what to inspect/replace.
- Clutch assembly (manual transmission vehicles)
- Components: clutch disc (friction plate), pressure plate, flywheel, release/throwout bearing, pilot bearing/bushing, clutch fork, slave and master cylinder (hydraulic systems), clutch cable (older models).
- Function: connects/disconnects engine from transmission so you can change gears. The pressure plate clamps the disc to the flywheel to transmit torque.
- Failures: worn clutch disc (slippage), glazed surfaces, warped flywheel, failing release bearing (noise when depressing pedal), leaking clutch hydraulics (soft pedal/air), broken springs.
- Inspect: clutch free play, pedal feel, smell of burning, ability to hold in gear, fluid level/lines.
- Transmission (manual or automatic)
- Components: gears/splines, synchros (manual), shafts, bearings, selectors, case, seals. Automatic includes torque converter, planetary gear sets, valve body, solenoids.
- Function: change gear ratios between engine and driveshaft to provide torque/speed.
- Failures: gear grinding, slipping, leaking seals, worn bearings, bad synchros (manual), torque converter or solenoids failing (auto), contaminated fluid.
- Inspect: fluid level/condition, noise in gear, difficulty engaging gears, whining or grinding.
- Transfer case (4WD vehicles)
- Components: chain or gear drive inside a case, mode fork/selector, front output and rear output, seals, control motor or lever (electronic or mechanical engagement), locking mechanisms (electronic locker, manual hub).
- Function: splits power between front and rear driveshafts; provides 4WD/2WD and sometimes low range.
- Failures: inability to engage 4WD, leaks, chain/gear wear, electrical actuator failure, internal bearing wear.
- Inspect: fluid level/condition, easy engagement/disengagement, unusual noise when shifting modes.
- Driveshaft / Propeller shaft (prop shaft)
- Components: tubular shaft, universal joints (U-joints) or CV joints, center support bearing (if multi-piece), slip yoke, flange yoke.
- Function: transmits rotation from transmission/transfer case to the differential(s).
- Failures: worn U-joints leading to clunks, vibration at speed, driveshaft imbalance, broken slip joint, damaged yokes.
- Inspect: play in U-joints, rust or looseness at flange bolts, center bearing wear, dents or bends in shaft.
- Universal joints (U-joints) and CV joints
- Components: cross and bearing caps (U-joint); outer and inner CV joints with boot (CV axle).
- Function: allow driveshaft to transmit torque while changing angle as suspension moves.
- Failures: worn bearings (play/knock), torn CV boots leading to grease loss and joint failure, clicking on turns (CV).
- Inspect: wiggle for play, listen for clicks under acceleration and turning, check boots for tears and grease.
- Differential (rear and front)
- Components: ring gear and pinion, bearings, carrier, spider gears (side gears), axle shafts, differential cover, seals, limited-slip or locking mechanism (if fitted).
- Function: splits driving torque between two wheels on an axle while allowing them to rotate at different speeds in turns.
- Failures: worn ring & pinion (noise, whining), bearing failure (growl), broken spider gears (locking issues), leaks at pinion or axle seals, contamination of oil.
- Inspect: fluid color/metal particles, backlash and gear contact pattern (requires dial indicator and marking compound), axle play, noisy under load.
- Axle shafts and wheel hubs
- Components: axle shaft, splines, hub bearing assembly, hub studs, flange.
- Function: transmit torque from differential to wheel; bearings allow wheel rotation.
- Failures: worn or broken splines, axle shaft bending, wheel bearing wear (rumble, play), hub studs shearing.
- Inspect: check for axial and radial play, noise when rotating wheel, hub run-out.
- Seals and gaskets
- Components: pinion seal, axle seals, differential cover gasket, transmission seals, transfer case seals.
- Function: hold lubricant in and keep contaminants out.
- Failures: leakage, contamination leading to low fluid and increased wear.
- Inspect: visible leaks, fluid levels, oil on surrounding components.
- Fluids and lubrication
- Components: engine oil, transmission fluid, differential gear oil, transfer case oil.
- Function: reduce friction, carry heat, and lubricate gear teeth/bearings.
- Failures: using wrong fluid, contamination, moisture in oil, low level causes overheating and wear.
- Inspect: fluid level and color, presence of metal flakes.
- Electronic controls and sensors (on modern D‑Max)
- Components: 4WD actuator motor/switch, ABS/traction sensors, diff lock controllers.
- Function: control engagement of electronic lockers and provide inputs for stability/trac control.
- Failures: failed actuator, wiring, or control module causing inability to engage 4WD or false warnings.
- Inspect: actuator operation, fuses, wiring continuity.
3) Typical symptoms and likely causes (quick reference)
- Vibration at speed: unbalanced or bent driveshaft, worn U-joints, wheel/tire imbalance, bad center bearing.
- Clunk when shifting into gear or letting out clutch: worn U-joint, worn transmission mounts, bad differential carrier bearings, loose pinion nut.
- Clicking when turning under acceleration: failed outer CV joint.
- Whining noise that changes with engine speed but not road speed: transmission or torque converter issue.
- Whine that changes with vehicle speed: differential ring & pinion, worn bearings.
- Gear slipping / gears pop out: worn gears, broken shift linkages, worn synchros (manual), low fluid.
- Leaks on ground or wet around housing: bad seals, gasket failure, cracked case.
- 4WD won’t engage: low transfer-case fluid, bad actuator, linkage, or internal damage.
4) Tools and supplies a beginner needs
- Basic: metric socket set, breaker bar, torque wrench, screwdrivers, pliers, hammer, pry bars.
- Specialty: jack and good quality jack stands, wheel chocks, transmission jack (or floor jack + blocks), snap ring pliers, bearing puller, press (or inertial puller), seal driver, impact wrench (helpful), heat gun or torch (for stuck parts).
- Consumables: penetrating oil, RTV or gasket maker (if required), replacement seals/gaskets, fresh gear/transmission/transfer case oil (manufacturer spec), rags, safety gloves.
- Diagnostic: dial indicator (for backlash), pry bar for play checks, grease gun (for greasable U-joints), torque screwdriver.
5) Safe general diagnostic and repair workflow (stepwise, high-level)
- Step 1: Document symptoms and history (noise type, when it happens, how long).
- Step 2: Visual inspection on the ground: look for leaks, torn boots, loose bolts, rust, missing grease.
- Step 3: Road test (safely): note conditions when problem occurs — speed, acceleration, turning, gear, 4WD engaged.
- Step 4: Lift and support vehicle safely on stands; remove wheels as needed.
- Step 5: Check for play: grab driveshaft/axle and try to move; check U-joint play; spin wheels to check bearings.
- Step 6: Check fluid levels/condition (trans, diff, transfer).
- Step 7: Remove/replace defective part or rebuild assembly. Clean everything and replace seals/gaskets and fluids.
- Step 8: Reassembly with correct torque specs; test drive and re-check.
6) Common repairs explained for a beginner (how to approach each, not absolute step-by-step)
Below are typical jobs you will do on the drivetrain and how to approach them.
- Replacing a U-joint
- Why: worn U-joints cause clunking and vibration.
- Approach: remove driveshaft from vehicle (mark alignment), use press or appropriate tool to press bearing caps out, fit new caps and greaseable caps if applicable, re-install shaft and torque flange bolts to spec.
- Tips: mark driveshaft orientation before removal to maintain balance; replace both joints on a shaft if one is bad; grease new joints if applicable.
- Replacing a CV axle (if used)
- Why: torn CV boot or clicking on turns indicates joint failure.
- Approach: remove wheel, hub nut, and disconnect lower control arm or hub as required; remove axle from hub and transmission/diff; install new axle, ensuring proper seating and axle circlip engagement; torque hub nut to spec.
- Tips: don’t hammer the transmission seal; use a puller or pry carefully; replace axle if boot is torn and joint contaminated.
- Driveshaft balancing/repair
- Why: dents or incorrect reassembly cause vibration at speed.
- Approach: inspect shaft for dents; if bent, replacement is often needed; short-term you can rebalance using weights at a shop.
- Tips: always reinstall driveshaft in the same orientation relative to companion flanges; if you experience vibration after U-joint replacement, check balance marks.
- Differential fluid change and inspection
- Why: old or contaminated oil reduces protection of gears and bearings and leads to premature wear.
- Approach: remove cover or drain plug, inspect for metal shavings, clean, refill with correct gear oil, replace cover gasket or sealant as needed.
- Tips: magnetic drain plug (if present) collects some metal; excessive metal indicates major wear—inspect internals or consult pro.
- Pinion seal replacement / bearing preload
- Why: leaking pinion seal causes fluid loss; incorrect bearing preload causes noise and rapid wear.
- Approach: this is advanced: remove driveshaft and yoke, remove pinion nut, take out pinion, replace seal and bearings, set bearing preload and backlash per service manual. This needs a dial indicator and torque specs.
- Tips: incorrect setup will quickly destroy the ring/pinion. If you’re not comfortable, have a differential shop set it up.
- Axle bearing or hub replacement
- Why: rumbling noise and play at wheel.
- Approach: remove wheel/hub assembly, press out old bearing, press in new one or replace hub assembly (bolt-on units are easier). Re-torque to spec.
- Tips: hub assemblies available as sealed units are much easier for beginners.
- Transmission or transfer case fluid service
- Why: fluid degrades and collects debris.
- Approach: drain and refill via fill plug or pan removal, replace filter if accessible (transmissions), use correct fluid and level with engine running if required (automatic transmissions).
- Tips: service intervals vary — check manual.
- Clutch replacement (manual)
- Why: slippage, dragging, or inability to change gears.
- Approach: remove transmission from bellhousing (this requires support and often removal of driveshaft and exhaust parts), remove clutch assembly and flywheel, inspect and resurfacing of flywheel or replacement, install new clutch kit and release bearing, align disc with tool, reassemble.
- Tips: do the job on a clean work area, replace pilot bearing and slave/master seals, always use alignment tool, torque bolts to spec. This is heavy and time-consuming; take your time.
7) Detailed inspection points for common failures (what to look for visually and by feel)
- U-joint: movement when twisting the driveshaft near the joint, visible rust or missing caps, seized cap.
- CV boot: grease on inside of wheel or undercarriage, torn boot, grease flung off.
- Differential: metal flakes in oil, strong burnt smell, noisy under load.
- Seals: oil on bodywork or dripping, oil on brake parts (dangerous — clean thoroughly).
- Transmission: burnt-smelling fluid, low fluid level, delayed engagement (automatic).
- Driveshaft: dents or deformation of the tube, loose flange bolts.
8) Troubleshooting quick-guide (symptom → likely cause → first check)
- Persistent vibration at ~40-60 km/h → unbalanced driveshaft or damaged U-joint → check driveshaft play and dents.
- Clunk on acceleration or shifting → worn U-joint, loose flange bolts, differential backlash → inspect flange bolts and joint play.
- Clicking when cornering → outer CV joint → inspect boot and joint play.
- Noise from rear that varies with vehicle speed → differential bearings or ring & pinion → check gear oil, metal in plug, and backlash.
- 4WD won’t engage → actuator/electronics, low transfer case fluid, linkage binding → check fuse, actuator operation, fluid level.
9) Maintenance tips to prevent big repairs
- Check and change differential and transfer case fluids at recommended intervals.
- Inspect boots and seals regularly; replace torn CV boots immediately.
- Greaseable U-joints: grease at intervals.
- Avoid severe clutch riding.
- If you leak any gear oil, fix immediately — low oil destroys bearings and gears fast.
- Keep fasteners torqued to spec — check after initial drive after service.
10) When to get a shop or specialist
- If diagnosis points to ring & pinion setup, pinion bearing preload, or internal differential gear contact pattern—you need a specialist or differential shop unless you have proper tools (dial indicator, torque wrench, depth gauge).
- If transmission internal problems (gear breakage, internal clutch packs in an automatic) — consider a transmission shop.
- If you don’t have safe lifting or a transmission jack for clutch removal, get help.
11) Final checklist before you drive after any drivetrain repair
- All bolts torqued to spec, flange alignment marks respected.
- Fluid levels correct and no leaks.
- Driveshaft orientation and balance marks reinstalled as removed.
- Test drive gradually and listen/check for new noises or vibration.
- Re-check torque on critical bolts after a short test drive where applicable.
Closing: This gives you the theory, the parts you’ll see on an Isuzu D‑Max drivetrain, what goes wrong, and how a beginner should approach diagnosis and repair. For any specific procedure (removal of transmission, pinion preload, torque values, fluid types, or actuator wiring), consult the exact year/model Isuzu Service Manual — those contain the step-by-step instructions, special tools, and torque specs you must follow.
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