ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Extension Housing Seal

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This procedure is for replacing the extension housing oil seal with the transmission installed in the vehicle.

REMOVAL & INSTALLATION

Models Without a Rear Transmission Flange

See Figure 1



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Fig. Fig. 1: After matchmarking the driveshaft to the differential flange, remove the 4 attaching bolts and nuts

Although draining the transmission is not necessary for this procedure, it would be a good time for a routine fluid change.

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. If so desired, drain the transmission fluid. For more information regarding automatic transmission fluid draining and fluid pan procedures, please refer to General Information & Maintenance of this repair guide.
  4.  
  5. Matchmark the rear driveshaft flange to the rear differential flange for reassembly.
  6.  
  7. Remove the 4 driveshaft retaining bolts from the rear differential.
  8.  
  9. If equipped, remove the center bearing retainer bolts.
  10.  
  11. Lower the rear of the driveshaft assembly down from the differential and pull the rear driveshaft front yoke gently free of the transmission extension housing. Remove the driveshaft assembly completely from the vehicle.
  12.  
  13. If equipped, remove the extension housing dust shield from the transmission.
  14.  
  15. Using an oil seal puller (usually a specially designed J-shaped prytool), remove the rear housing oil seal.
  16.  

To install:
  1. Install a new oil seal using an installer tool (such as J-37239 for the AW30-80LE transmission) which is the correct size to drive the new seal into the extension housing, or the equivalent. Start the new oil seal into the extension housing, position the installation tool against it and gently tap the new oil seal into the transmission with a mallet. Make certain that the oil seal is seated completely and flush in the rear extension housing bore.
  2.  
  3. Lubricate the inside lip of the fluid oil seal with fresh, clean transmission fluid.
  4.  
  5. Position the driveshaft assembly under the vehicle, then lift the front end of the driveshaft up and slide it carefully into the rear extension housing of the transmission.
  6.  
  7. If applicable, lift the center bearing up and install the retaining bolts finger-tight. Position the rear driveshaft flange against the differential flange so the matchmarks align and install the attaching bolts and nuts finger-tight. Make sure the driveshaft-to-differential bolts are installed from the backside of the differential flange (the threaded portion of the bolt should be toward the front of the vehicle).
  8.  
  9. If equipped, tighten the center bearing bolts to 45 ft. lbs. (60 Nm).
  10.  
  11. Tighten the driveshaft-to-differential flange bolts and nuts to 46 ft. lbs. (63 Nm).
  12.  
  13. If necessary, install a new transmission fluid filter and the fluid pan. For more details, refer to General Information & Maintenance .
  14.  
  15. Lower the vehicle.
  16.  
  17. Start the engine and test drive the transmission. After driving the vehicle, look for transmission fluid leaks from the rear oil seal.
  18.  

Models With a Rear Transmission Flange

These vehicles are equipped with a transmission-to-driveshaft flange; rather than sliding the driveshaft yoke into the rear extension housing, the driveshaft bolts to the transmission flange.

Although draining the transmission is not necessary for this procedure, it would be a good time for a routine fluid change.

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. If desired, drain the transmission fluid. For more information on automatic transmission fluid and filter service refer to General Information & Maintenance .
  4.  
  5. Matchmark the rear driveshaft flange to the rear differential flange and the front driveshaft flange to the rear transmission flange for reassembly.
  6.  
  7. Remove the 4 driveshaft retaining bolts from the rear differential.
  8.  
  9. If equipped, remove the center bearing retainer bolts.
  10.  
  11. Remove the 4 driveshaft retaining bolts from the transmission rear flange.
  12.  
  13. Lower the rear of the driveshaft assembly out of the vehicle.
  14.  
  15. Use a rear flange holding tool to hold the rear flange steady while loosening the flange retaining nut.
  16.  
  17. Remove the flange retaining nut and the old O-ring. Discard the O-ring.
  18.  
  19. Using an oil seal removal tool, pry the old oil seal out of the extension housing.
  20.  

To install:
  1. Apply a film of clean engine oil to the inner lip of the oil seal, then install it into the transmission extension housing with an oil seal installation tool.
  2.  
  3. Install a new O-ring onto the transmission rear flange and install the flange nut.
  4.  
  5. Use the flange holding tool to hold the flange stationary while tightening the flange nut to 76 ft. lbs. (103 Nm).
  6.  
  7. Position the driveshaft assembly under the vehicle, then lift the front end of the driveshaft up and hold it against the transmission flange so the matchmarks align. Install the driveshaft-to-transmission flange bolts and nuts finger-tight.
  8.  
  9. If applicable, lift the center bearing up and install the retaining bolts finger-tight. Position the rear driveshaft flange against the differential flange so the matchmarks align and install the attaching bolts and nuts finger-tight. Make sure the driveshaft-to-differential bolts are installed from the backside of the differential flange (the threaded portion of the bolt should be toward the front of the vehicle).
  10.  
  11. If equipped, tighten the center bearing bolts to 45 ft. lbs. (60 Nm).
  12.  
  13. Tighten the driveshaft-to-differential flange and driveshaft-to-transmission flange bolts and nuts to 46 ft. lbs. (63 Nm).
  14.  
  15. If necessary, install a new transmission fluid filter and the fluid pan. For more details, refer to General Information & Maintenance .
  16.  
  17. Lower the vehicle.
  18.  
  19. Start the engine and test drive the transmission. After driving the vehicle, look for transmission fluid leaks from the rear oil seal.
  20.  

 
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