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

Transmission

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REMOVAL & INSTALLATION



MSG-Type Transmissions
1981-88 PICK-UP AND TROOPER MODELS

See Figures 1, 2, 3, 4 and 5

This procedure covers all 1981-88 Pick-Ups and Trooper models equipped with MSG-type transmissions.

  1. Disconnect the negative battery cable.
  2.  
  3. Block the rear wheels from rolling and apply the parking brake, then raise and safely support the vehicle on jackstands.
  4.  
  5. Position a drain pan large enough to hold a minimum of 5-6 qts. (4.7-5.7L) under the transmission drain plug. Clean the dirt from around the drain and filler plugs, then remove the filler plug first. Remove the drain plug and allow the transmission to drain completely into the catch pan. Once the transmission is completely drained, install the filler and rain plugs hand-tight.
  6.  
  7. Remove the transmission gear shift lever and, if equipped, the transfer case gear shift lever. For more information, refer to the shift handle removal and installation procedures earlier in this section.
  8.  
  9. Remove the starter motor from the engine.
  10.  
  11. Detach the speedometer cable from the transmission by loosening the speedometer cable retaining ring and pulling the cable end out of the transmission. Be careful when pulling the cable out of the transmission, the speedometer gear may be damaged.
  12.  
  13. Matchmark the front, if applicable, and rear driveshafts to the differential flanges. Remove the front and rear driveshafts. For more details, refer to the driveshaft removal and installation procedures located later in this section.
  14.  
  15. Disconnect the clutch cable from the clutch lever. For more information, refer to the clutch linkage removal and installation procedures later in this section.
  16.  
  17. Remove the flywheel stone guard.
  18.  
  19. Remove the transfer case from the transmission, as described later in this section.
  20.  
  21. Remove the transmission frame member mounting bolts, then lower the frame member off the vehicle. Move it aside.
  22.  


WARNING
Support the rear of the engine while the transmission is removed from the vehicle, otherwise the engine will shift and can cause damage to the engine mounts and other components.

  1. Using an engine hoist, or similar supporting tool, support the rear of the engine from falling. Once the transmission is removed, the rear of the engine will have no support and will definitely fall.
  2.  
  3. Support the transmission with a transmission jack, or similar hydraulic floor jack, and remove the rear mount bolts and nuts.
  4.  
  5. Remove the transmission mounting bolts. Rotate the transmission assembly axially (around an axis which runs from the front of the vehicle to the back) 90 degrees clockwise to ease removal.
  6.  
  7. Slowly lower the transmission assembly out of the vehicle with the transmission jack.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Before removing the transmission, remove the filler plug and drain the transmission fluid into a catch pan



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Fig. Fig. 2: Separate the frame bracket from the transmission by removing the 2 rear mount bolts



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Fig. Fig. 3: To ease removal, rotate the transmission axially 90 degrees as shown



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Fig. Fig. 4: When installing the transmission, turn the transmission on its right side as when the transmission was removed



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Fig. Fig. 5: When attaching the driveshaft to the transmission flange, if equipped, insert the bolts in from the extension flange

To install:
  1. Position the transmission at the rear of the engine with the transmission jack and with the transfer case side facing down. Slide the input shaft into the clutch disc hub and rotate the transmission 90 degrees counterclockwise along the same axis as when removed. Install the mounting bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Install the frame-to-rear housing mount bolts and tighten until secure.
  4.  
  5. Install the transfer case to the transmission by aligning the grooves in the shift arms and shift sleeves, while held in the 2H position. Tighten the transfer case-to-transmission retaining bolts to 34 ft. lbs. (46 Nm).
  6.  
  7. Install the flywheel stone guard and clutch cable.
  8.  
  9. Install the driveshafts, making certain that the matchmarks on the differential flanges and driveshaft flanges align. If applicable, tighten the center bearing bolts to 46 ft. lbs. (65 Nm). Tighten the driveshaft-to-differential bolts to 22 ft. lbs. (30 Nm).
  10.  
  11. Install the speedometer cable, starter motor, shift levers and boots.
  12.  
  13. If not already done, install the drain plug. Remove the filler plug and refill the transmission with 30W SAE engine oil. Install the fill plug and tighten the fill plug and drain plug to 25 ft. lbs. (34 Nm).
  14.  
  15. Lower the vehicle and remove the wheel blocks.
  16.  
  17. Connect the negative battery cable.
  18.  

1989-95 AMIGO AND PICK-UP MODELS
  1. Disconnect the negative and positive battery cables.
  2.  
  3. Remove the battery.
  4.  
  5. Support the hood as far open as possible. If you choose to remove the hood, first matchmark the hood hinge plates with a felt-tipped marker.
  6.  
  7. Remove the console and shift boot. Unbolt the shift lever from the transmission case and remove it. Cover the quadrant box hole to prevent contaminants from entering the transmission.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Drain the transmission oil. Install the drain plug with a new washer.
  12.  
  13. If equipped with a two-piece driveshaft, remove the center bearing retainer bolts.
  14.  
  15. Matchmark the driveshaft to transmission and differential flanges. Remove the driveshaft.
  16.  
  17. Remove the starter.
  18.  
  19. Disconnect the speedometer cable.
  20.  
  21. Disconnect the clutch cable from the release fork.
  22.  
  23. Remove the exhaust pipe bracket from the transmission case. Disconnect the front exhaust pipe from the exhaust manifold and disconnect the second exhaust pipe.
  24.  
  25. Use a lifting chain or jack to support the engine. Support the transmission with a jack.
  26.  
  27. Remove the rear housing mount from the transmission. Remove the mount bracket from the No. 3 crossmember.
  28.  
  29. Remove the quadrant box from the transmission.
  30.  

The frame crossmember may interfere with transmission removal. An assistant will be helpful for shifting the transmission back and away from the engine.

  1. Position a jack under the transmission and remove the transmission case bolts. Move the transmission as far to the rear of the vehicle as possible to clear the mainshaft. Then, lower the clutch housing end of the transmission toward the jack and lower the transmission from the vehicle.
  2.  

To install:
  1. Using a transmission jack, position the transmission-to-engine and tighten the retaining bolts to 28 ft. lbs. (37 Nm). Install the quadrant box.
  2.  
  3. Install the mount bracket and tighten the bolt to 27 ft. lbs. (37 Nm).
  4.  
  5. Install the frame-to-rear housing mount bolts at the No. 3 crossmember. Tighten the rear mount nut to 62 ft. lbs. (83 Nm).
  6.  
  7. Tighten the engine mount nuts to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the exhaust pipe and bracket.
  10.  
  11. Install the driveshaft and align the matchmarks. Tighten the center bearing bolts to 46 ft. lbs. (65 Nm). Position the retaining bolts with the head facing to the rear of the vehicle and tighten to 22 ft. lbs. (30 Nm).
  12.  
  13. Install the speedometer cable and starter motor. Tighten the starter motor bolts to 30 ft. lbs. (40 Nm).
  14.  
  15. Reconnect and adjust the clutch cable.
  16.  
  17. Lower the vehicle and install the shift lever, shift boot, and console.
  18.  
  19. Refill the transmission with the proper type of oil.
  20.  
  21. Install the battery and reconnect the positive and negative cables.
  22.  
  23. Install the hood if it was removed.
  24.  

MUA-Type Transmissions
1988-95 2WD AMIGO AND PICK-UP
  1. Disconnect the negative and positive battery cables.
  2.  
  3. Remove the battery.
  4.  
  5. Support the hood as far open as possible. If you choose to remove the hood, first matchmark the hood hinge plates with a felt-tipped marker.
  6.  
  7. Remove the console and shift boot. Unbolt the shift lever from the transmission case and remove it. Cover the quadrant box hole to prevent contaminants from entering the transmission.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Drain the transmission oil. Install the drain plug with a new washer.
  12.  
  13. If equipped with a two-piece driveshaft, remove the center bearing retainer bolts.
  14.  
  15. Matchmark the driveshaft flanges to the differential and transmission flanges. Remove the driveshaft.
  16.  
  17. Remove the starter.
  18.  
  19. Disconnect the speedometer cable.
  20.  
  21. Unbolt the slave cylinder from the side of the transmission case. Don't disconnect the hydraulic line.
  22.  
  23. Remove the exhaust pipe bracket from the transmission case. Disconnect the front exhaust pipe from the exhaust manifold and the second exhaust pipe.
  24.  
  25. Support the engine with a lifting chain or jack. Support the transmission with a jack.
  26.  
  27. Remove the rear housing mount from the transmission. Remove the mount bracket from the third crossmember.
  28.  
  29. Remove the quadrant box from the transmission.
  30.  

The frame crossmember may interfere with transmission removal. An assistant will be helpful for shifting the transmission back and away from the engine.

  1. Position a jack under the transmission and remove the engine-to-transmission bolts. Move the transmission as far to the rear of the vehicle as possible, and then lower the clutch housing end of the transmission toward the jack.
  2.  

To install:
  1. Using a transmission jack, position the transmission-to-engine and tighten the retaining bolts to 28 ft. lbs. (37 Nm). Install the quadrant box.
  2.  
  3. Install the mount bracket and tighten the bolt to 27 ft. lbs. (37 Nm).
  4.  
  5. Install the frame-to-rear housing mount bolts at the No. 3 crossmember, and tighten to 62 ft. lbs. (83 Nm).
  6.  
  7. Tighten the engine mount nuts to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the exhaust pipe and bracket.
  10.  
  11. Align the matchmarks and install the driveshaft. Tighten the center bearing bolts to 46 ft. lbs. (65 Nm). Position the retaining bolts with the head facing rearward and tighten to 22 ft. lbs. (30 Nm).
  12.  
  13. Install the speedometer cable and starter motor. Tighten the starter motor bolts to 30 ft. lbs. (40 Nm).
  14.  
  15. Install the slave cylinder. If necessary, refill and bleed the clutch hydraulic system.
  16.  
  17. Refill the transmission with the proper type of oil.
  18.  
  19. Lower the vehicle and install the shift lever, boot, and console.
  20.  
  21. Install the battery and reconnect the positive and negative cables.
  22.  
  23. Install the hood if it was removed.
  24.  

1988-95 4WD AMIGO AND PICK-UP

The transmission and transfer case are removed from the vehicle as a unit. Once removed, the transmission and transfer case can be separated for servicing.

  1. Disconnect the negative and positive battery cables.
  2.  
  3. Remove the battery.
  4.  
  5. Support the hood as far open as possible. If you choose to remove the hood, first matchmark the hood hinge plates with a felt-tipped marker.
  6.  
  7. Remove the console and shift boots. Unbolt the shift levers from the transmission case and remove them. Cover the quadrant box hole to prevent contaminants from entering the transmission.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Drain the transmission oil. Install the drain plug with a new washer.
  12.  
  13. Remove the transfer case skid plates.
  14.  
  15. Disconnect the speedometer cable.
  16.  
  17. Remove the starter motor and the clutch slave cylinder. Don't disconnect the hydraulic lines.
  18.  
  19. Mark the driveshafts to the differential flanges and remove the front and rear driveshafts.
  20.  
  21. Remove the exhaust pipe bracket from the transmission case. Disconnect the front exhaust pipe from the exhaust manifold and the second exhaust pipe.
  22.  
  23. Support the engine with a lifting chain or jack.
  24.  
  25. Remove the crossmember and transmission mount.
  26.  
  27. Support the transmission with a jack.
  28.  
  29. Remove the transmission-to-engine bolts.
  30.  

The frame crossmember may interfere with transmission removal. An assistant will be helpful for shifting the transmission back and away from the engine.

  1. Move the transmission toward the rear of the vehicle. Then, slowly lower it from the vehicle using the jack.
  2.  

To install:
  1. Raise the transmission into position.
  2.  
  3. With an assistant, install the transmission to the engine. Make sure the input shaft is splined properly into the clutch disc. Tighten the mounting bolts to 28 ft. lbs. (37 Nm).
  4.  
  5. Install the crossmember and tighten the mounting bolts to 27 ft. lbs. (37 Nm).
  6.  
  7. Install the transmission mount and tighten the nut to 62 ft. lbs. (83 Nm).
  8.  
  9. Install the exhaust pipe and bracket.
  10.  
  11. Install the front and rear driveshafts in the marked locations. Tighten the flange bolts to 43 ft. lbs. (63 Nm).
  12.  
  13. Reconnect the speedometer cable.
  14.  
  15. Install the starter motor and tighten the bolts to 30 ft. lbs. (40 Nm).
  16.  
  17. Install the slave cylinder. If necessary, refill and bleed the clutch hydraulic system.
  18.  
  19. Refill the transmission and transfer case with the proper type of oil.
  20.  
  21. Install the transfer case skid plates.
  22.  
  23. Lower the vehicle and install the shift levers, boots, and console.
  24.  
  25. Install the battery and reconnect the positive and negative cables.
  26.  
  27. Install the hood if it was removed.
  28.  

1988-91 TROOPER

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. Drain the transmission and transfer case oil.
  2.  
  3. Remove the transfer case undercover, starter motor, speedometer cable and gear shift levers.
  4.  
  5. Remove the front exhaust pipes (2.8L V6 only).
  6.  
  7. Mark the driveshafts to the flanges and remove the front and rear driveshafts.
  8.  
  9. Leave the clutch slave cylinder fluid hose connected and remove the cylinder from the transmission and support it out of the way.
  10.  
  11. Raise the transmission slightly with a jack and remove the crossmember and transmission mount. Support the engine with an adjustable stand.
  12.  
  13. Remove the transmission mounting bolts.
  14.  
  15. With an assistant, remove the transmission/transfer case as an assembly.
  16.  

To install:
  1. With an assistant, raise the transmission to the rear of the engine and install the transmission mounting bolts. Make sure the input shaft splines align properly with the clutch disc.
  2.  
  3. Install the clutch slave cylinder and crossmember.
  4.  
  5. Install the front exhaust pipe on vehicles equipped with 2.8L engine.
  6.  
  7. Install the front and rear driveshafts in the marked locations.
  8.  
  9. Install the speedometer cable, starter motor and gear shift lever.
  10.  
  11. Refill the transmission and transfer case with the specified amount of SAE 30 oil.
  12.  
  13. Install the undercover and connect the negative battery cable.
  14.  

1992-96 TROOPER

See Figures 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

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. Shift the transmission into N . Shift the transfer case into 2H and drive the vehicle forward and backward a few feet/meters to make sure the front axle is not engaged.
  2.  
  3. Use a felt-tipped marker to matchmark the hood to the hood hinges. Remove the hood.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the shift knobs and the console and shift boots.
  8.  
  9. Remove the shift lever and the transfer case shift lever, by unbolting their mounting plates from the transmission case.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: After raising the vehicle, detach the oxygen sensor connector from the transmission



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Fig. Fig. 7: Remove the heat protector and the clutch hydraulic system slave cylinder



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Fig. Fig. 8: Before disconnecting the driveshafts from the differentials, matchmark the flanges



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Fig. Fig. 9: Remove the speed sensor attaching bolt, then pull the sensor from the transmission housing



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Fig. Fig. 10: Remove the 2 wiring harness retaining clamps from the harness



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Fig. Fig. 11: Locations of the 2 rear transfer case-to-vehicle frame attaching bolts



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Fig. Fig. 12: Use the special tool J-39207, or equivalent, to disconnect the clutch release bearing from the clutch pressure plate



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Fig. Fig. 13: Insert J-39207, between the wedge collar and the release bearing, then ...



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Fig. Fig. 14: ... twist the tool to separate the release bearing from the pressure plate



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Fig. Fig. 15: Align the top gear shaft spline with the clutch driven plate spline, then push the transmission against the engine



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Fig. Fig. 16: When installing the transmission-to-engine bolts, make sure they are installed in their proper locations



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Fig. Fig. 17: Apply force to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing



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Fig. Fig. 18: Apply grease to the top hole portion of the shift fork, then install the slave cylinder

  1. Raise and safely support the vehicle.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove the exhaust and transfer case skid plates.
  6.  
  7. Label and disconnect the oxygen sensor connectors from the transmission harness.
  8.  
  9. Remove the catalytic converter, left front, and center exhaust pipes.
  10.  
  11. Remove the harness heat protector.
  12.  
  13. Remove the slave cylinder heat protector. Unbolt and remove the slave cylinder. Don't disconnect the hydraulic line.
  14.  
  15. Remove the slave cylinder dust covers.
  16.  
  17. Matchmark the driveshafts at the their flanges. Unbolt and remove the driveshafts.
  18.  
  19. Label and disconnect the reverse light switch, 4WD indicator switch, and 1-2 and 3-4 indicator switch harness connectors.
  20.  
  21. Disconnect the speed sensor harness connector.
  22.  
  23. Remove the 2 harness clamps from the transmission case.
  24.  
  25. Using a transmission jack, raise the transmission slightly. Remove the 2 rear transmission mounting nuts.
  26.  
  27. Remove the center crossmember (8 bolts).
  28.  
  29. Attach a chain hoist to the engine lifting brackets, but don't raise the engine yet.
  30.  
  31. Remove the front crossmember.
  32.  

Make sure the engine assembly is properly supported when removing the front crossmember.

  1. Remove the 3 flywheel inspection cover bolts.
  2.  
  3. Use the clutch release bearing remover J-39207, or an equivalent, pry tool to release the bearing from the pressure plate. Push the release fork toward the rear of the vehicle. Insert the tool between the release bearing and the pressure plate collar. Move the lever toward the rear to pry.
  4.  
  5. Raise the engine slightly with a chain hoist and remove the bolts and nuts securing the transmission to the engine.
  6.  
  7. Carefully pull the transmission rearward. Lower the transmission from the vehicle.
  8.  

To install:

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. Apply a thin coating of molybdenum grease to the spline of the input shaft, slowly raise the transmission into position with the rear of the engine. Align the splines of the input shaft with the grooves of the clutch disc hub and install thetransmission to the engine.
  2.  

It may be helpful the put the transmission in gear and rotate the driveshaft flange so the input shaft will turn and engage the grooves in the clutch disc hub.

  1. Install the transmission case bolts. Tighten the upper 6 bolts to 56 ft. lbs. (76 Nm). Tighten the 2 remaining large bolts to 56 ft. lbs. (76 Nm). Tighten the remaining 3 bolts to 5.2 inch lbs. (6 Nm).
  2.  
  3. Push the release bearing fork rearward with a force of 13-18 lbs. (59-78 N) to engage the release bearing with the pressure plate. A click sound will be heard when the bearing engages the pressure plate properly.
  4.  
  5. Install the flywheel inspection cover.
  6.  
  7. Install the front crossmember and the front driveshaft. Tighten the crossmember bolts to 58 ft. lbs. (78 Nm). Tighten the driveshaft flange bolts to 46 ft. lbs. (60 Nm).
  8.  
  9. Install the rear crossmember and mount. Tighten the crossmember mounting bolts to 37 ft. lbs. (50 Nm) and the transmission mounting nuts to 30 ft. lbs. (41 Nm).
  10.  
  11. Remove the transmission jack and the engine hoist.
  12.  
  13. Connect the transmission harness connectors and install the harness clamps.
  14.  
  15. Install the rear driveshaft and tighten the flange bolts to 46 ft. lbs. (60 Nm).
  16.  
  17. Apply grease to the dimple on the end of the release bearing fork and install the slave cylinder, heat protector, and dust covers. Tighten the slave cylinder bolts to 32 ft. lbs. (43 Nm). Tighten the dust cover bolts to 5.2 ft. lbs. (6 Nm).
  18.  
  19. Install the exhaust pipes and heat protectors using new self-locking nuts. Tighten the exhaust manifold flange bolts to 49 ft. lbs. (67 Nm). Tighten the center pipe flange bolts to 32 ft. lbs. (43 Nm) for 1995-96 vehicles. On 1992-94 vehicles: tighten the center pipe flange bolts to 37 ft. lbs. (50 Nm); and tighten the converter bolts to 25 ft. lbs. (34 Nm).
  20.  
  21. Connect the oxygen sensor connectors.
  22.  
  23. Refill the transmission with the correct fluid.
  24.  
  25. Install the skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  26.  
  27. Lower the vehicle to the floor.
  28.  
  29. Install the shift levers. Tighten the shift lever mounting plate bolts to 15 ft. lbs. (20 Nm).
  30.  
  31. Install the console, shift boots, and shift knobs.
  32.  
  33. Align the matchmarks and install the hood.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Check the operation of the clutch and starter. Road test the vehicle.
  38.  

1991 RODEO
  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the engine hood and cooling fan. Place the fan on the fan guide.
  4.  
  5. Place the shift lever in Neutral, pull up the shift lever grommet and dust cover. Remove the gear shift lever. Cover the opening with a rag to prevent dirt from entering the transmission.
  6.  
  7. Remove the suspension crossmember.
  8.  
  9. Remove the starter motor assembly.
  10.  
  11. Remove the clutch slave cylinder from the transmission. Be careful not to allow the cylinder piston from falling out of the bore.
  12.  
  13. Remove the rear driveshaft.
  14.  
  15. Disconnect the exhaust pipe from the manifold and catalytic converter and remove the pipe.
  16.  
  17. Disconnect all electrical connectors and speedometer cable from the transmission.
  18.  
  19. Remove the flywheel dust cover.
  20.  
  21. Attach an engine lifting cable to the engine hanger and take the engine weight off the crossmember. Remove the center crossmember.
  22.  
  23. Install a transmission jack under the transmission and remove the retaining nuts and bolts. Remove the assembly from the vehicle.
  24.  

To install:
  1. Install a transmission jack under the transmission and install the transmission into the vehicle. Install the retaining nuts and bolts.
  2.  
  3. Install the center crossmember. Lower the engine onto the crossmember. Install the retaining nuts and bolts.
  4.  
  5. Install the flywheel dust cover.
  6.  
  7. Connect all electrical connectors and speedometer cable to the transmission.
  8.  
  9. Connect the exhaust pipe to the manifold and catalytic converter.
  10.  
  11. Install the rear driveshaft.
  12.  
  13. Install the clutch slave cylinder to the transmission. Be careful not to allow the cylinder piston from falling out of the bore.
  14.  
  15. Install the starter motor assembly.
  16.  
  17. Install the suspension crossmember.
  18.  
  19. Install the gear shift lever.
  20.  
  21. Install the engine hood and cooling fan.
  22.  
  23. Connect the negative (-) battery cable and check operation.
  24.  

1992-96 RODEO

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. Shift the transmission into N . Shift the transfer case into 2H and drive the vehicle forward and backward a few feet/meters to make sure the front axle is not engaged.
  2.  
  3. Use a felt-tipped marker to matchmark the hood to the hood hinges. Remove the hood.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the shift knobs and the console and shift boots.
  8.  
  9. Remove the shift lever and the transfer case shift lever (if equipped), by unbolting their mounting plates from the transmission case.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Drain the oil from the transmission and transfer case.
  14.  
  15. Remove the exhaust and transfer case skid plates.
  16.  
  17. Disconnect the oxygen sensor connector from the transmission harness.
  18.  
  19. Unbolt the exhaust flanges. Separate and remove the catalytic converter, left front, and center exhaust pipes.
  20.  
  21. Remove the harness heat protector.
  22.  
  23. Remove the slave cylinder heat protector. Unbolt and remove the slave cylinder. Don't disconnect the hydraulic line.
  24.  
  25. Remove the slave cylinder dust covers.
  26.  
  27. Matchmark the driveshafts at the flanges and remove them.
  28.  
  29. Disconnect the reverse light switch, 4WD indicator switch, 1-2 and 3-4 indicator switch harness connectors.
  30.  
  31. Disconnect the speed sensor harness connector.
  32.  
  33. Remove the 2 harness clamps from the transmission case.
  34.  
  35. Attach a chain hoist to the engine.
  36.  
  37. Using a transmission jack, raise the transmission slightly. Remove the 2 rear transmission mounting nuts.
  38.  
  39. Remove the center crossmember (8 bolts).
  40.  
  41. On 4WD vehicles, remove the front crossmember and the front driveshaft.
  42.  

Make sure the engine assembly is properly supported when removing the front crossmember.

  1. Remove the 3 flywheel inspection cover bolts.
  2.  
  3. Use clutch release bearing remover J-39207 or an equivalent pry tool to release the bearing from the pressure plate. Push the release fork toward the rear of the vehicle. Insert the tool between the release bearing and the pressure plate collar. Move the lever to the rear to pry.
  4.  
  5. Raise the engine slightly with a chain hoist and remove the bolts and nuts securing the transmission to the engine.
  6.  
  7. Carefully pull the transmission rearward. Lower the transmission from the vehicle.
  8.  

To install:
  1. Apply a thin coating of molybdenum grease to the splines of the input shaft, and then slowly raise the transmission into position against the rear of the engine. Align the splines of the input shaft with the grooves of the clutch disc hub and install the transmission to the engine.
  2.  

It may be helpful the put the transmission in gear and rotate the driveshaft flange so the input shaft will turn and engage the grooves in the clutch disc hub.

  1. Install the transmission case bolts. Tighten the upper 6 bolts to 56 ft. lbs. (76 Nm). Tighten the 2 remaining large bolts to 56 ft. lbs. (76 Nm). Tighten the remaining 3 bolts to 4.4 ft. lbs. (6 Nm).
  2.  
  3. Push the release bearing fork rearward with a force of 13-18 lbs. (59-78 N) to engage the release bearing with the pressure plate. A click sound will be heard when the bearing engages the pressure plate properly.
  4.  
  5. Install the flywheel inspection cover.
  6.  
  7. On 4WD vehicles, install the front crossmember and the front driveshaft. Tighten the crossmember bolts to 58 ft. lbs. (78 Nm). Tighten the driveshaft flange bolts to 46 ft. lbs. (60 Nm).
  8.  
  9. Install the center crossmember and transmission mount. Tighten the center crossmember mounting bolts to 37 ft. lbs. (50 Nm) and the transmission mounting nuts to 30 ft. lbs. (41 Nm).
  10.  
  11. Remove the transmission jack and the engine hoist.
  12.  
  13. Connect the transmission harness connectors and install the harness clamps.
  14.  
  15. Install the rear driveshaft and tighten the flange bolts to 46 ft. lbs. (63 Nm).
  16.  
  17. Apply grease to the dimple on the end of the release bearing fork and install the slave cylinder, heat protector, and dust covers. Tighten the slave cylinder bolts to 32 ft. lbs. (43 Nm). Tighten the dust cover bolts to 4.4 ft. lbs. (6 Nm).
  18.  
  19. Install the exhaust pipes and heat protectors using new self-locking nuts. Tighten the exhaust manifold flange bolts to 49 ft. lbs. (67 Nm). Tighten the center pipe flange bolts to 32 ft. lbs. (43 Nm).
  20.  
  21. Refill the transmission and transfer case with the proper type and quantity of oil.
  22.  
  23. Install the skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  24.  
  25. Lower the vehicle to the floor.
  26.  
  27. Install the transmission and transfer case shift levers. Tighten the shift lever mounting plate bolts to 15 ft. lbs. (20 Nm).
  28.  
  29. Install the console, shift boots, and shift knobs.
  30.  
  31. Align the matchmarks and install the hood.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Check the operation of the clutch and starter. Road test the vehicle.
  36.  

Borg-Warner T5R Transmission
RODEO MODELS

See Figure 19

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. Shift the transmission into Neutral. Remove the gearshift and transfer case shift knobs.
  4.  
  5. Remove the 4 console screws and lift the console and shift boot over the shift levers.
  6.  
  7. Unbolt and remove the shift lever and its cover plate from the transmission case. If equipped, remove the transfer case shift lever.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Drain the transmission oil.
  12.  
  13. Disconnect and remove the starter.
  14.  
  15. Unbolt the the slave cylinder from the transmission case. Don't disconnect the hydraulic line.
  16.  
  17. Matchmark the driveshaft U-joints to the transmission and differential flanges.
  18.  
  19. If the vehicle is equipped with 4WD; matchmark the front driveshaft U-joints to the differential and transfer case.
  20.  

On 4WD vehicles, the transfer case skid plates and front exhaust pipe must be removed before removing the front driveshaft.

  1. Remove the driveshaft and the center bearing.
  2.  
  3. Disconnect the front exhaust pipe from the manifold and the catalytic converter. It is not necessary to remove the exhaust pipe from the chassis.
  4.  
  5. Disconnect the reverse and neutral switch connectors from the transmission.
  6.  
  7. Disconnect the speedometer cable or speed sensor connector from the transmission.
  8.  
  9. Remove the flywheel inspection cover.
  10.  
  11. Support the transmission with a transmission jack.
  12.  
  13. Raise the transmission slightly so the jack supports its weight.
  14.  
  15. Support the rear of the engine with a jack or chain hoist.
  16.  
  17. Unbolt and remove the center crossmember and the transmission mount.
  18.  
  19. With the engine and transmission supported, remove the bolts securing the transmission case to the engine.
  20.  
  21. Pull the transmission away from the engine so the mainshaft clears the pressure plate. Remove the transmission from the vehicle.
  22.  



Click image to see an enlarged view

Fig. Fig. 19: The rear of the transmission is secured to the crossmember by 2 transmission mount attaching nuts

To install:
  1. Apply a thin coating of molybdenum grease to the splines of the mainshaft and raise the transmission to the rear of the engine. Align the shaft splines with the clutch driven plate splines. Push the transmission toward the engine to engage the splines of the mainshaft with the grooves in the clutch disc hub. Install the mounting bolts and nuts.
  2.  
  3. Tighten the 10mm transmission case bolts and nuts to 28-30 ft. lbs. (37-40 Nm). Tighten the 6mm bolts to 4.4 ft. lbs. (6 Nm).
  4.  
  5. Install the center crossmember to the frame. Then, install the transmission mount. Tighten the crossmember bolts to 56 ft. lbs. (76 Nm) and the mount nuts to 30 ft. lbs. (41 Nm).
  6.  
  7. Remove the transmission jack and engine lifting equipment.
  8.  
  9. Install the flywheel dust cover.
  10.  
  11. Connect the speedometer cable or speed sensor connector.
  12.  
  13. Connect the reverse and neutral switch connectors.
  14.  
  15. Install the exhaust pipe using new self-locking nuts. Tighten the exhaust flange nuts to 49 ft. lbs. (67 Nm).
  16.  
  17. Install the driveshafts. Tighten the center bearing bolts to 45 ft. lbs. (60 Nm). Tighten the flange bolts to 46 ft. lbs. (63 Nm).
  18.  
  19. Install the skid plates, if equipped. Tighten the skid plate bolts to 27 ft. lbs. (37 Nm).
  20.  
  21. Coat the tip of the slave cylinder with molybdenum grease. Install the slave cylinder assembly and tighten the bolts to 37 ft. lbs. (50 Nm).
  22.  
  23. Install the starter and tighten the bolts to 30 ft. lbs. (40 Nm).
  24.  
  25. Refill the transmission with the proper type and quantity of oil.
  26.  
  27. Lower the vehicle.
  28.  
  29. Lubricate the shift ball and lower edge of the shift lever. Install the gearshift lever assembly to the transmission case and tighten the bolts to 15 ft. lbs. (20 Nm). On 4WD vehicles, install the transfer case lever.
  30.  
  31. Install the shift boot(s), console, and shift knob(s).
  32.  
  33. Connect the negative battery cable.
  34.  

NV1500 Transmission

The NV1500 came equipped on the 1996 Hombre vehicles. This transmission is only 2-wheel drive.

Shift the transmission into 3rd or 4th gear position.

  1. Disconnect the negative battery cable.
  2.  


WARNING
Refer to the Shift Lever removal and installation procedures before attempting to remove the shift lever housing.

  1. Remove the shift lever and the shift housing.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the parking brake cable for clearance.
  6.  
  7. Remove the propeller shaft.
  8.  
  9. Detach the wiring harness connectors from the speed sensor and back-up switch.
  10.  
  11. Remove the wiring harness retainers from the right side of the transmission.
  12.  
  13. Detach the muffler from the catalytic converter.
  14.  
  15. Disconnect the exhaust pipes from the exhaust manifold.
  16.  
  17. Remove the catalytic converter hanger and exhaust section.
  18.  
  19. Remove the 2 bolts and nut securing the transmission left side brace to the engine and transmission. Remove the 2 bolts securing the transmission right side brace to the engine and transmission.
  20.  
  21. Detach the hydraulic clutch quick-connect from the concentric slave cylinder following 1 of the 2 steps:
    1. Use 2 small prytools at 180 degrees from each other to depress the white plastic sleeve on the quick connect to separate the clutch line from the concentric slave cylinder quick connect.
    2.  
    3. Use special tool J-36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect.
    4.  

  22.  
  23. Remove the 4 bolts securing the clutch housing cover to the transmission.
  24.  
  25. Remove the clutch plate and clutch cover from the flywheel-for more details, refer to the clutch assembly removal and installation procedure later in this section. Support the transmission with a suitable jack.
  26.  
  27. Properly relieve the fuel pressure, then remove the fuel lines and fuel line retainers from the rear crossmember.
  28.  
  29. Remove the rear crossmember from the frame rail.
  30.  
  31. Detach the wiring harness from the front crossmember. Move the wiring harness away from the transmission oil pan. Lower the transmission enough to gain access to the top of the transmission.
  32.  
  33. Remove the fuel line retainers from the top of the transmission.
  34.  
  35. Remove the bolt, washer, and nut securing the wiring harness ground wires to the engine block. Unfasten the 5 bolts retaining the transmission to the engine. Pull the transmission straight back on the clutch hub splines.
  36.  
  37. Lower the transmission using the transmission jack.
  38.  

To install:
  1. Raise the transmission using the jack.
  2.  
  3. Attach the fuel line retainers to the top of the transmission.
  4.  
  5. Install the 5 bolts securing the transmission to the engine. Push the transmission straight back onto the hub splines. Tighten the bolts to 66 ft. lbs. (90 Nm).
  6.  
  7. Install the bolt, washer and nut securing the wiring harness ground wires to the engine block. Tighten the nut to 66 ft. lbs. (90 Nm).
  8.  
  9. Install the wiring harness to front crossmember retainer.
  10.  
  11. Tighten the rear crossmember-to-frame rail bolts until secure.
  12.  
  13. Secure the fuel lines to the rear crossmember.
  14.  
  15. Install the clutch plate and clutch cover to the flywheel. For more information, refer to the clutch assembly removal and installation procedure later in this section.
  16.  
  17. Install the 4 clutch housing cover-to-transmission case bolts. Tighten them to 62 inch lbs. (7 Nm).
  18.  
  19. Attach the hydraulic clutch line to the concentric slave cylinder quick-disconnect fitting.
  20.  
  21. Install the 2 bolts securing the transmission right-hand side brace to the engine and transmission. Also install the 2 bolts and nut securing the transmission left-hand side brace to the engine and transmission. Tighten the bolts and nuts to 37 ft. lbs. (50 Nm).
  22.  
  23. Install the catalytic converter hanger and the exhaust section. Attach the exhaust pipes to the exhaust manifold and the muffler to the catalytic converter. For more details refer to the end of Engine and Engine Rebuilding for exhaust system procedures.
  24.  
  25. Attach the wiring harness retainers to the right-hand side of the transmission.
  26.  
  27. Install the wiring harness connectors to the back-up lamp switch and to the speed sensor.
  28.  
  29. Install the driveshaft. For more details, refer to the driveshaft removal and installation procedure later in this section.
  30.  
  31. Install the parking brake cable, as described in Brakes of this repair guide.
  32.  
  33. Install the shift housing and shift lever. For more details, refer to the shift lever removal and installation procedure earlier in this section.
  34.  
  35. Lower the vehicle and connect the negative battery cable.
  36.  

 
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