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

Transmission Assembly

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REMOVAL & INSTALLATION



AW03-55 and AW03-75 Transmissions
1981-87 PICK-UP MODELS

See Figures 1, 2, 3, 4, and 5



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Fig. Fig. 1: To disconnect the throttle cable, loosen the adjust nuts and detach the joint pin from the carburetor lever



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Fig. Fig. 2: To access the torque converter-to-flexplate bolts and nuts, remove the dust cover and the torque converter inspection cover



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Fig. Fig. 3: When installing the flexplate mounting bolts, make certain to tighten the bolts in a crisscross pattern, as shown



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Fig. Fig. 4: Make sure there is the appropriate amount of clearance between the converter housing and the front face of the converter



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Fig. Fig. 5: When installing the driveshaft-to-transmission flange bolts, insert them from the tail housing flange side

  1. Disconnect the negative battery cable. Raise and safely support the vehicle on jackstands.
  2.  
  3. Remove the transmission dipstick assembly.
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Disconnect and plug the oil cooler lines from the transmission.
  8.  
  9. Remove the torque converter cover. Matchmark the torque converter at the flywheel, and remove the torque converter bolts from the flywheel; rotate the torque converter to expose the bolts.
  10.  
  11. Remove the exhaust pipe nuts from the exhaust manifold, and separate the pipe from the manifold.
  12.  
  13. Disconnect the shift lever control rod from the transmission shift lever.
  14.  
  15. Disconnect the neutral safety switch and transmission wiring from the transmission.
  16.  
  17. Support the engine assembly.
  18.  
  19. Remove the starter motor and disconnect the speedometer cable from the transmission.
  20.  
  21. Matchmark and remove the driveshaft.
  22.  
  23. Remove the transmission-to-crossmember bolts.
  24.  
  25. Lift the engine/transmission slightly with a hydraulic floor jack and remove the transmission frame bracket from the crossmember. Remove the rear mount from the crossmember. Remove the exhaust pipe bracket from the transmission.
  26.  
  27. Support the transmission with a transmission floor jack.
  28.  
  29. Remove the bell housing-to-engine bolts and the transmission from the vehicle.
  30.  

Be careful that the torque converter does not drop from the transmission.

To install:
  1. Raise the transmission on a jack and install the bell housing bolts to the engine. Tighten the bolts to 29 ft. lbs. (39 Nm).
  2.  

Make sure the torque convertor is fully seated in the transmission. If the transmission does not mount flush to the engine block during installation, check the torque convertor. Do not use the bolts to pull the transmission flush to the engine block or damage may occur.

  1. Install the torque converter-to-flywheel bolts. Tighten the bolts to 14 ft. lbs. (19 Nm). Install the flywheel cover.
  2.  
  3. Support the transmission with a hydraulic floor jack.
  4.  
  5. Lift the engine/transmission slightly and install the transmission frame bracket to the crossmember. Install the rear mount to the crossmember.
  6.  
  7. Install the exhaust pipe bracket to the transmission.
  8.  
  9. Install the driveshaft.
  10.  
  11. Install the transmission-to-crossmember bolts.
  12.  
  13. Install the starter motor and connect the speedometer to the transmission.
  14.  
  15. Remove the engine and transmission support floor jacks.
  16.  
  17. Connect the neutral safety switch and transmission wiring to the transmission.
  18.  
  19. Connect the shift lever control rod to the transmission shift lever.
  20.  
  21. Install the exhaust pipe nuts to the exhaust manifold.
  22.  
  23. Reconnect the cooler lines and install the transmission dipstick assembly.
  24.  
  25. Lower the vehicle and refill the transmission.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Run the engine until it reaches normal temperature. Raise the drive wheels off the ground and run the transmission through all gears and recheck fluid. Make sure the vehicle is supported safely and DO NOT overfill the transmission.
  30.  

AW30-80LE Transmission
1988-89 PICK-UP AND 1988-91 TROOPER MODELS

The transfer case is an integral part of the transmission housing. Although the 2 cases can be separated, the transfer case should be removed with the transmission.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the undercover, if equipped.
  6.  
  7. Drain the transmission fluid from the oil pan. For more information, refer to General Information & Maintenance .
  8.  
  9. Loosen the throttle cable adjusting nuts and disconnect the throttle cable from the bracket. Remove the transmission dipstick.
  10.  
  11. Disengage the wiring connectors at the neutral safety switch.
  12.  
  13. Unbolt the starter motor and place it aside in a safe location. Support the starter so it does not strain the electrical connections.
  14.  
  15. Remove the front driveshaft, as described later in this section.
  16.  
  17. Remove the 1-piece rear driveshaft at the flanges, as described in this section.
  18.  
  19. Disconnect the shift cable at the transmission and transfer case, if equipped.
  20.  
  21. Disconnect the speedometer cable from the transmission.
  22.  
  23. Disconnect the oil cooler lines and position the cooler bypass line close to the transmission case to prevent damage during transmission removal.
  24.  
  25. Remove the engine rear dust cover.
  26.  
  27. Remove the torque converter attaching bolts. The bolts can be removed through the starter hole.
  28.  
  29. Remove the front exhaust pipe from the exhaust manifold.
  30.  
  31. Place a transmission jack under the transmission and raise it slightly.
  32.  
  33. Remove the nuts connecting the rear mount to the transmission.
  34.  
  35. Remove the nuts and bolts connecting the rear mount to the crossmember, then remove the mount.
  36.  
  37. Remove the transmission mounting bolts.
  38.  
  39. Move the transmission back and carefully lower the transmission out of the vehicle. Do not let the torque converter fall out of the transmission.
  40.  

To install:

Installation of the transmission will require an assistant.

  1. Make sure the torque converter if fully seated in the transmission. The correct distance from the converter to the mounting surface is 1.02 in. (31mm).
  2.  
  3. Raise the rear of the transmission and move it into position on the crossmember.
  4.  
  5. Move the transmission forward and engage it with the engine.
  6.  

If the transmission does not seat flush against the engine block before the bolts are installed, check to see that the torque converter is seated properly in the transmission, do not use the bolts to draw the transmission against the engine block.

  1. Install the transmission mounting bolts and tighten them to 47 ft. lbs. (64 Nm).
  2.  
  3. Install the rear mount to the crossmember.
  4.  
  5. Install the rear mount-to-transmission nuts.
  6.  
  7. Install the bolts attaching the flexplate to the torque converter through the starter hole and tighten them to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the engine rear dust cover.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold. Refer to Engine & Engine Overhaul for the correct procedures concerning the exhaust system components.
  12.  
  13. Connect the oil cooler lines, speedometer cable and shift linkage.
  14.  
  15. Install the front and rear driveshafts, as described later in this section.
  16.  
  17. Install the starter motor. For more details, refer to Engine Electrical .
  18.  
  19. Connect the downshift cable to the transmission.
  20.  
  21. Install the oil level dipstick and the tube.
  22.  
  23. Refill the transmission with the correct type and amount of transmission fluid. For more information, refer to General Information & Maintenance .
  24.  
  25. Install the undercover, if equipped.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  

AW03-72L Transmission
1988-95 PICK-UP AND 1992-94 AMIGO MODELS

See Figure 6



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Fig. Fig. 6: Disconnect the throttle cable from the throttle body lever by sliding the end of the cable out of the groove in the lever

  1. Disconnect the negative battery cable. Raise and safely support the vehicle on jackstands.
  2.  
  3. Drain the transmission fluid from the oil pan. For more details on fluid and filter servicing, refer to General Information & Maintenance .
  4.  
  5. Detach the throttle cable at the engine end and remove the transmission dipstick.
  6.  
  7. Unbolt the starter motor and position it aside in a safe location. Support the starter so it does not strain the electrical connections.
  8.  
  9. If equipped with a 1-piece driveshaft, remove the driveshaft flange nuts at the pinion, lower the driveshaft and pull it from the transmission.
  10.  
  11. If equipped with a 2-piece driveshaft, perform the following procedures:
    1. Remove the rear driveshaft flange nuts at the pinion.
    2.  
    3. Remove the rear driveshaft flange bolts from the front driveshaft flange. Remove the rear driveshaft.
    4.  
    5. Remove the center bearing bolts from the chassis, move the front driveshaft rearward and from the transmission.
    6.  

  12.  
  13. Disconnect the shift control rod at the shifter end.
  14.  
  15. Disconnect the speedometer cable from the transmission.
  16.  
  17. Disconnect the oil cooler lines and position the cooler bypass line close to the transmission case to prevent damage during transmission removal.
  18.  
  19. Remove the torque converter bolts from the flexplate through the starter hole.
  20.  
  21. Place a transmission jack under the transmission and raise it slightly.
  22.  
  23. Remove the rear mount nuts from the transmission.
  24.  
  25. Remove the rear mount nuts and bolts from the crossmember. Remove the mount.
  26.  
  27. Remove the transmission-to-engine bolts.
  28.  
  29. Move the transmission back and lower the transmission out of the vehicle.
  30.  

To install:

Installation of the transmission will require an assistant.

  1. Raise the transmission into position.
  2.  
  3. Raise the rear of the transmission and move it into position on the crossmember.
  4.  
  5. Move the transmission forward and engage it with the engine.
  6.  
  7. Install the engine-to-transmission bolts and tighten them to 47 ft. lbs. (64 Nm).
  8.  

Make sure the torque converter is seated properly. The transmission should mount flush to the engine block; if the transmission does not mount flush, check the torque convertor. Do not use the mounting bolts to pull the transmission flush to the engine or torque converter damage may occur.

  1. Install the mount and the rear mount nuts and bolts to the crossmember.
  2.  
  3. Install the rear mount nuts to the transmission. Tighten them to 30 ft. lbs. (41 Nm).
  4.  
  5. Install the torque converter bolts to the flexplate through the starter hole, and tighten them to 22 ft. lbs. (30 Nm).
  6.  
  7. Connect the oil cooler lines, speedometer cable, and shift linkage.
  8.  
  9. If equipped with a 2-piece driveshaft, perform the following procedure:
    1. Install the front driveshaft into the transmission.
    2.  
    3. Install the center bearing bolts to the chassis.
    4.  
    5. Install the rear driveshaft flange bolts to the transmission rear flange.
    6.  
    7. Install the rear driveshaft flange nuts to the differential pinion flange. For more details, refer to the driveshaft procedures later in this section.
    8.  

  10.  
  11. If equipped with a 1-piece driveshaft, install the driveshaft into the transmission and the driveshaft flange nuts to the opinion flange.
  12.  
  13. Install the starter motor, as described in Engine Electrical .
  14.  
  15. Connect the throttle (downshift) cable to the transmission.
  16.  
  17. Install the oil level dipstick and the tube.
  18.  
  19. Refill the transmission with the proper type and amount of transmission fluid. For more details, refer to General Information & Maintenance .
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for leaks.
  24.  

THM4L30-E Transmission
1990-91 TROOPER MODELS

The transfer case is an integral part of the transmission housing. Although the 2 cases can be separated, the transfer case should be removed with the transmission.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the center and rear console from inside of the passenger's compartment.
  4.  
  5. Remove the transfer case control lever.
  6.  
  7. Raise and safely support the vehicle on jackstands.
  8.  
  9. Disconnect the shift control rod from the transmission, as described earlier in this section.
  10.  
  11. Remove the 2 piece undercover for access to the crankshaft balancer for turning the crankshaft as needed.
  12.  
  13. Disconnect the center bearing bracket and remove the rear driveshaft. Remove the front driveshaft. For more information, refer to the driveshaft procedures later in this section.
  14.  
  15. Disconnect the parking brake cable at the equalizer.
  16.  
  17. Disconnect the speedometer cable at the transfer case.
  18.  
  19. Remove the left front exhaust pipe.
  20.  
  21. Disconnect and plug the fluid cooling lines from the transmission.
  22.  
  23. Remove the starter motor, as described in Engine Electrical .
  24.  
  25. Disengage the harness connector from the inhibitor switch.
  26.  
  27. Detach the 5 electrical connectors from the transmission.
  28.  
  29. Remove the breather hose from the top of the transmission.
  30.  
  31. Remove the flexplate inspection cover.
  32.  
  33. Remove the 3 bolts securing the torque converter to the flexplate. Use a socket on the crankshaft center bolt to rotate or hold the crankshaft as needed.
  34.  
  35. Remove the transmission undercovers, lift up the transmission slightly with a hydraulic transmission floor jack and remove the 3rd crossmember with the rear engine mount.
  36.  
  37. Remove the exhaust pipe and catalytic converter, as described in Engine & Engine Overhaul .
  38.  
  39. Remove the dipstick and tube with the bracket.
  40.  
  41. Remove the transmission mounting bolts, pull the transmission slightly rearward and carefully lower the transmission from the vehicle. Be careful not to drop the torque converter out of the transmission.
  42.  

Support the rear of the engine with an engine hoist or an hydraulic floor jack while the transmission and/or transfer case is removed.

To install:
  1. Make sure the torque converter is fully seated in the front pump and slowly raise the transmission into position until the front is flush with the rear of the engine. Install the transmission mounting bolts and tighten them to 29 ft. lbs. (39 Nm).
  2.  

If the transmission does not seat flush against the engine block before the bolts are installed, check to see that the torque converter is seated properly in the transmission, do not use the bolts to draw the transmission to the engine block.

  1. Install the dipstick tube with the bracket.
  2.  
  3. Install the exhaust pipe and catalytic converter, as described in Engine & Engine Overhaul .
  4.  
  5. Install the 3rd crossmember and rear mount. Tighten the crossmember bolts to 37 ft. lbs. (50 Nm) and the mount nuts to 30 ft. lbs. (41 Nm).
  6.  
  7. Remove the transmission jack and engine support.
  8.  
  9. Align the torque converter bolt boss with the starter opening on the torque converter housing by turning the torque converter. Turn the crankshaft to align the bolt hole in the flexplate with the boss in the torque converter, then install the bolts. Tighten the 3 bolts to 41 ft. lbs. (55 Nm).
  10.  
  11. Install the inspection cover on the flexplate and install the transmission undercovers.
  12.  
  13. Install the breather hose and all electrical connectors on the transmission.
  14.  
  15. Install the starter motor.
  16.  
  17. Connect the transmission fluid cooling lines to the transmission. Tighten the line fittings to 33 ft. lbs. (44 Nm).
  18.  
  19. Install the left front exhaust pipe.
  20.  
  21. Connect the speedometer cable to the transmission.
  22.  
  23. Connect the parking brake cable to the equalizer.
  24.  
  25. Install the front and rear driveshafts, as described later in this section.
  26.  
  27. Install the 2 piece undercover.
  28.  
  29. Connect the shift linkage to the transmission; adjust if necessary.
  30.  
  31. Lower the vehicle, then install the transfer case control lever and the center console assembly.
  32.  
  33. Connect the negative battery cable, start the engine and check the transmission fluid level. Add fluid as needed.
  34.  

1992-96 TROOPER AND 1991-96 RODEO MODELS

See Figures 7, 8, 9, 10 and 11



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Fig. Fig. 7: Disengage the oxygen sensor connector from the transmission wiring harness connector



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Fig. Fig. 8: Detach the selector lever end of the shift lock cable from the lever assembly by loosening the adjusting nuts and sliding the end out of the bracket



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Fig. Fig. 9: Disconnect the shift control rod from the selector lever lower lever arm



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Fig. Fig. 10: Remove the oil pipe clamp bracket from the engine stiffener



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Fig. Fig. 11: Make certain to tighten the transmission-to-engine mounting bolts to the proper amount of torque-the torque measurements are shown in parentheses

The transfer case is an integral part of the transmission housing. Although the 2 cases can be separated, the transfer case should be removed with the transmission.

  1. Use a felt-tipped marker to matchmark the hood to the hood hinges. Remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Shift the transmission into the N position, and the transfer case into the 2H position.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the transfer case shift knob. Remove the 4 transmission cover console retaining screws.
  10.  
  11. Remove the center console assembly and disengage the console switch wiring connectors.
  12.  
  13. Disconnect the shift lock cable and the shift control rod from the selector lever assembly.
  14.  
  15. Unbolt and remove the transfer case control lever.
  16.  
  17. Raise and safely support the vehicle on jackstands.
  18.  
  19. Remove the transmission and transfer case skid plates.
  20.  
  21. Remove the exhaust pipe protectors.
  22.  
  23. Drain the transmission fluid. For more information servicing the transmission fluid pan and filter, refer to General Information & Maintenance .
  24.  
  25. Label and detach the oxygen sensor connectors.
  26.  
  27. Remove the catalytic converter, center exhaust pipe and front exhaust pipe, as described in Engine & Engine Overhaul .
  28.  
  29. Matchmark the front and rear driveshafts to the differential and transfer case flanges.
  30.  
  31. Unbolt and remove the front and rear driveshafts, as described later in this section.
  32.  
  33. Disconnect the oil cooler lines from the transmission. Plug the lines to prevent fluid loss and contamination.
  34.  
  35. Remove the brackets securing the oil cooler lines to the engine stiffener.
  36.  
  37. Remove the front suspension crossmember.
  38.  
  39. Remove the dipstick and tube. Disconnect the breather hoses from the tube.
  40.  
  41. Remove the 5 engine stiffener bracket bolts and the stiffener bracket.
  42.  
  43. Remove the heat protector.
  44.  
  45. Disengage the transmission harness connectors and the mode switch harness connector from the engine harness.
  46.  
  47. Disconnect the harness clamp from the clamp bracket.
  48.  
  49. Disconnect the ground cable from the engine.
  50.  
  51. Remove the starter motor, as described in Engine Electrical .
  52.  
  53. Remove the flexplate inspection cover.
  54.  
  55. Remove the 3 bolts securing the flexplate to the torque converter. Turn the crankshaft to gain access to all 3 bolts.
  56.  

Remove the radiator upper fan shroud and the cooling fan to access the crankshaft center bolt to turn the crankshaft.

  1. Place a suitable transmission jack under the transmission and transfer case unit for support.
  2.  
  3. Raise the transmission slightly and remove the 8 bolts securing the rear mount and the transmission crossmember.
  4.  

Make sure the engine and transmission assembly is properly supported before removing the rear mount and third crossmember.

  1. Raise the engine slightly with an engine hoist and remove the transmission-to-engine bolts.
  2.  
  3. Separate the transmission from the engine and lower the transmission from the vehicle.
  4.  

To install:

Use new self-locking nuts when reconnecting the exhaust system. Replace any color-coded self-locking bolts when installing the frame crossmembers.

  1. Install the transfer case onto the transmission case, if the 2 cases were separated.
  2.  
  3. Install a new O-ring on the front pump shaft.
  4.  

Make sure the transmission dowel pins are installed in the correct position. If the dowels are in the wrong hole, the transmission case may crack.

  1. Make sure the torque converter is fully seated in the front pump and slowly raise the front of the transmission into position until it is flush with the rear of the engine. Install the transmission-to-engine bolts and tighten the upper 6 mounting bolts to 56 ft. lbs. (76 Nm) and the lower 3 mounting bolts to 35 ft. lbs. (48 Nm). Tighten the remaining 2 bolts to 52 inch lbs. (6 Nm).
  2.  
  3. Install the third crossmember. Tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the rear mount and lower the engine from the hoist. Tighten the rear mount nuts to 30 ft. lbs. (41 Nm).
  6.  
  7. Remove the transmission jack and the engine hoist.
  8.  
  9. Install the flexplate-to-torque converter bolts. Tighten the bolts in a crisscross pattern to 41 ft. lbs. (55 Nm).
  10.  
  11. Install the flexplate inspection cover.
  12.  
  13. Attach the transmission and mode switch harness connectors to the engine harness.
  14.  
  15. Connect the harness clamp to the bracket and radiator clip.
  16.  
  17. Connect the ground cable to the engine.
  18.  
  19. Install the starter motor and tighten the mounting bolts to 30 ft. lbs. (40 Nm).
  20.  
  21. Install the heat protector.
  22.  
  23. Install the stiffener bracket. Tighten the attaching bolts to 35 ft. lbs. (48 Nm).
  24.  
  25. Install the transmission dipstick tube and dipstick. Connect the breather hoses to the tube.
  26.  
  27. Install the front crossmember, then tighten the bolts to 58 ft. lbs. (79 Nm).
  28.  
  29. Connect the transmission fluid cooling lines to the transmission. Tighten the line fittings to the following specifications:

    1992-94 Trooper models-33 ft. lbs. (44 Nm)
     
    1991-94 Rodeo models-33 ft. lbs. (44 Nm)
     
    1995-96 Trooper and Rodeo models-40 ft. lbs. (54 Nm)
     

  30.  
  31. Install the front and rear driveshafts. Tighten the flange bolts to 46 ft. lbs. (64 Nm).
  32.  
  33. Install the exhaust pipes and the catalytic converter. Tighten the manifold nuts to 49 ft. lbs. (67 Nm). On 1995-96 vehicles, tighten the center pipe and converter bolts to 32 ft. lbs. (43 Nm). On 1992-94 vehicles, tighten the center pipe bolts to 37 ft. lbs. (50 Nm), and the converter bolts to 25 ft. lbs. (34 Nm).
  34.  
  35. Reattach the oxygen sensor connectors.
  36.  
  37. Install the exhaust pipe protectors.
  38.  
  39. Install the skid plates and tighten their mounting bolts to 27 ft. lbs. (37 Nm).
  40.  
  41. Refill the transmission with DEXRON® ATF.
  42.  
  43. Lower the vehicle.
  44.  
  45. Install the transfer case control lever.
  46.  
  47. Connect the shift control rod to the selector lever.
  48.  
  49. Attach the console switch connectors and the shift lock cable to the selector lever. Adjust the shifter linkage and shift lock cable cable, as described earlier in this section.
  50.  
  51. Install the center console assembly and the transfer case lever knob.
  52.  
  53. Install the upper fan shroud and the cooling fan.
  54.  
  55. Install the air cleaner assembly.
  56.  
  57. Align the matchmarks and install the hood.
  58.  
  59. Connect the negative battery cable.
  60.  
  61. Start the engine and shift through the gear range 3 times to circulate the ATF through the valve body.
  62.  
  63. Recheck the fluid level and add if necessary.
  64.  
  65. Road test the vehicle.
  66.  

 
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