Isuzu Cars and Trucks 1981-1991

Transmission

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REMOVAL AND INSTALLATION
RWD I-Mark and Impulse
  1. Disconnect the battery cables and raise the vehicle. Make sure it is supported safely.
  2.  
  3. Remove the transmission dipstick. Drain the fluid into a suitable container and discard.
  4.  
  5. Remove the starter toward the front of the vehicle.
  6.  
  7. Disconnect the drive shaft from the central joint, then slide the propeller shaft rearward and remove it.
  8.  
  9. Disconnect the shift control rod from the shift lever.
  10.  
  11. Disconnect the speedometer cable.
  12.  
  13. Remove the exhaust pipe bracket.
  14.  
  15. Disconnect the oil cooler lines by loosening the joint nuts at the transmission.
  16.  


NOTE
Secure the cooler lines closer to the body to avoid damage during transmission removal.

  1. Remove the four bolts attaching the converter housing lower cover and remove the cover.
  2.  
  3. Remove the lower cover on the front part of the engine to permit turning of the engine and torque converter.
  4.  
  5. Remove the six bolts fastening the torque converter and drive plate by turning the crankshaft pulley.
  6.  
  7. Remove the bolt on the center part of the rear mounting from bracket.
  8.  
  9. Raise the engine and transmission using a suitable jack and support the rear end of the engine to hold it in position when the transmission is removed.
  10.  
  11. Remove the four bolts or nuts securing the rear mounting frame bracket, then remove the bracket.
  12.  
  13. Lower the transmission slightly then remove the bolts and nuts fixing the converter housing, then remove the transmission toward the rear.
  14.  


CAUTION
When removing the transmission, exercise care so as not to let the torque converter slide out.

To install:

  1. Raise the transmission with a transmission jack and install the bolts and nuts fixing the converter housing.
  2.  
  3. Install the four bolts or nuts securing the rear mounting frame bracket.
  4.  
  5. Raise the engine and transmission using a suitable jack and support the rear end of the engine to hold it in position when the transmission is installed.
  6.  
  7. Install the bolt on the center part of the rear mounting to bracket.
  8.  
  9. Install the six bolts fastening the torque converter and drive plate by turning the crankshaft pulley.
  10.  
  11. Install the cover and four bolts attaching the converter housing lower cover.
  12.  
  13. Connect the oil cooler lines by tightening the joint nuts at the transmission.
  14.  
  15. Install the exhaust pipe bracket.
  16.  
  17. Connect the speedometer cable.
  18.  
  19. Connect the shift control rod to the shift lever.
  20.  
  21. Connect the drive shaft to the central joint.
  22.  
  23. Install the starter toward the front of the vehicle.
  24.  
  25. Install the transmission dipstick and refill the fluid.
  26.  
  27. Connect the battery cables and raise the vehicle. Make sure it is supported safely.
  28.  
  29. Run the engine until it reaches normal temperature. Run the transmission through all gears and recheck fluid. Make sure the vehicle is supported safely and DO NOT overfill the transmission.
  30.  

P'up, Amigo, Trooper and Rodeo
2-WHEEL DRIVE VEHICLES 1981 and 1987
  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Remove the undercover, if equipped.
  4.  
  5. Remove the transmission dipstick assembly. Drain the transmission fluid. Disconnect and plug the oil cooler lines from the transmission.
  6.  
  7. Remove the torque converter cover. Matchmark the torque converter-to-flywheel location and remove the torque converter-to-flywheel bolts; rotate the torque converter to expose the bolts.
  8.  
  9. Remove the exhaust pipe-to-exhaust manifold nuts and separate the pipe from the manifold.
  10.  
  11. Disconnect the shift lever control rod from the transmission shift lever.
  12.  
  13. Disconnect the back-up light switch and transmission wiring from the transmission.
  14.  
  15. Using an engine hoist, connect it to the engine hangers and support the engine.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove the starter motor. Disconnect the speedometer from the transmission.
  20.  
  21. Matchmark and remove the driveshaft. Remove the transmission-to-crossmember bolts.
  22.  
  23. Lift the engine/transmission slightly and remove the transmission frame bracket from the crossmember. Remove the rear mount from the crossmember. Remove the exhaust pipe bracket from the transmission.
  24.  
  25. Support the transmission.
  26.  
  27. Remove the bell housing-to-engine bolts and the transmission from the vehicle.
  28.  


NOTE
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-to-engine bolts.
  2.  
  3. Support the transmission.
  4.  
  5. Lift the engine/transmission slightly and install the transmission frame bracket to the crossmember. Install the rear mount to the crossmember. Install the exhaust pipe bracket to the transmission.
  6.  
  7. Install the driveshaft. Install the transmission-to-crossmember bolts.
  8.  
  9. Install the starter motor. Connect the speedometer to the transmission.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the engine support.
  14.  
  15. Connect the back-up light switch and transmission wiring to the transmission.
  16.  
  17. Connect the shift lever control rod to the transmission shift lever.
  18.  
  19. Install the exhaust pipe-to-exhaust manifold nuts and tighten.
  20.  
  21. Install the torque converter-to-flywheel bolts and flywheel cover.
  22.  
  23. Reconnect the cooler lines. Install the transmission dipstick assembly and refill the transmission.
  24.  
  25. Install the undercover, if equipped.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Run the engine until it reaches normal temperature. Run the transmission through all gears and recheck fluid. Make sure the vehicle is supported safely and DO NOT overfill the transmission.
  30.  

2-WHEEL DRIVE VEHICLES 1988 and 1990
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the undercover, if equipped.
  4.  
  5. Label and disconnect the necessary hoses and electrical connectors.
  6.  
  7. Remove the back-up light switch connector and the speedometer cable from the transmission.
  8.  
  9. Remove the gear shift lever by performing the following procedures:
  10.  
    1. Place the gear shift lever in N .
    2.  
    3. Remove the front console from the floor panel.
    4.  
    5. Pull the shift lever boot and grommet upward.
    6.  
    7. Remove the shift lever cover bolts and the shift lever.
    8.  

  11. Raise and safely support the vehicle. Remove the front wheels.
  12.  
  13. Drain the transmission fluid.
  14.  
  15. Remove the oil level gauge and the tube.
  16.  
  17. Disconnect the shift select control link rod from the select lever.
  18.  
  19. Disconnect the downshift cable from the transmission.
  20.  
  21. Disconnect and plug the fluid coolant lines from the transmission.
  22.  
  23. If equipped with a 1-piece driveshaft, remove the driveshaft flange-to-pinion nuts, lower the driveshaft and pull it from the transmission.
  24.  
  25. If equipped with a 2-piece driveshaft, perform the following procedures:
  26.  
    1. Remove the rear driveshaft flange-to-pinion nuts.
    2.  
    3. Remove the rear driveshaft flange-to-front driveshaft flange bolts and the rear driveshaft.
    4.  
    5. Remove the center bearing-to-chassis bolts, move the front driveshaft rearward and from the transmission.
    6.  

  27. Remove the starter-to-engine bolts and the starter.
  28.  
  29. Remove the exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts and the front exhaust pipe from the vehicle.
  30.  
  31. Attach an engine hanger to the rear of the exhaust manifold.
  32.  
  33. Using an engine hoist, connect it to the engine hangers and support the engine.
  34.  


NOTE
Removal of the transmission will require an assistant.

  1. Remove the torque converter-to-flex plate bolts through the starter hole.
  2.  
  3. Using a transmission jack, place it under the transmission; do not support it.
  4.  
  5. Remove the rear mount-to-transmission nuts.
  6.  
  7. Remove the rear mount-to-crossmember nuts/bolts and the mount.
  8.  
  9. Remove the transmission-to-engine bolts.
  10.  
  11. Move the transmission rearward into the crossmember and floor pan area; the transmission may rest on the crossmember.
  12.  
  13. Lower the front of the transmission toward the jack.
  14.  
  15. Firmly, grasp the transmission the rear cover while the assistant raises the jack toward the transmission.
  16.  
  17. Carefully, lower the transmission onto the jack and center it.
  18.  
  19. Lower the jack and move the transmission rearward.
  20.  

To install:


NOTE
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.
  8.  
  9. Install the mount and the rear mount-to-crossmember nuts/bolts.
  10.  
  11. Install the rear mount-to-transmission nuts.
  12.  
  13. Install the torque converter-to-flex plate bolts through the starter hole.
  14.  
  15. Remove the engine hoist and the engine hanger from the rear of the exhaust manifold.
  16.  
  17. Install the front exhaust pipe, exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts.
  18.  
  19. Install the starter and the starter-to-engine bolts.
  20.  
  21. If equipped with a 2-piece driveshaft, perform the following procedures:
  22.  
    1. Install the front driveshaft into the transmission and the center bearing-to-chassis bolts.
    2.  
    3. Install the rear driveshaft and the rear driveshaft flange-to-front driveshaft flange bolts.
    4.  
    5. Install the rear driveshaft flange-to-pinion nuts.
    6.  

  23. If equipped with a 1-piece driveshaft, install the driveshaft into the transmission and the driveshaft flange-to-pinion nuts.
  24.  
  25. Connect the fluid coolant lines to the transmission.
  26.  
  27. Connect the downshift cable to the transmission.
  28.  
  29. Connect the shift select control link rod to the select lever.
  30.  
  31. Install the oil level gauge and the tube.
  32.  
  33. Install the front wheels and lower the vehicle.
  34.  
  35. Install the gear shift lever by performing the following procedures:
  36.  
    1. Install the shift lever and the shift lever cover bolts.
    2.  
    3. Push the grommet and shift lever boot downward.
    4.  
    5. Install the front console to the floor panel.
    6.  

  37. Install the back-up light switch connector and the speedometer cable to the transmission.
  38.  
  39. Connect the necessary hoses and electrical connectors.
  40.  
  41. Refill the transmission. Install the undercover, if equipped.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Run the engine until it reaches normal temperature. Run the transmission through all gears and recheck fluid. Make sure the vehicle is supported safely and DO NOT overfill the transmission.
  46.  
  47. Run the engine and check for leaks.
  48.  

4-WHEEL DRIVE VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the undercover, if equipped.
  4.  
  5. Remove the air cleaner (4ZD1 engine) or air cleaner duct and hose (4ZE1 engine). Using a clean shop cloth, cover the air cleaner port to prevent dirt from entering the engine.
  6.  
  7. Label and disconnect the necessary hoses and electrical connectors.
  8.  
  9. Remove the back-up light switch connector and the speedometer cable from the transmission.
  10.  
  11. Remove the gear shift lever by performing the following procedures:
  12.  
    1. Place the gear shift lever in N .
    2.  
    3. Remove the front console from the floor panel.
    4.  
    5. Pull the shift lever boot and grommet upward.
    6.  
    7. Remove the shift lever cover bolts and the shift lever.
    8.  

  13. Remove the transfer shift lever by performing the following procedures:
  14.  
    1. Place the transfer shift lever in H (except 2.8L engine) or 2H (2.8L engine).
    2.  
    3. Pull the shift lever boot and dust cover upward.
    4.  
    5. Remove the shift lever retaining bolts.
    6.  
    7. Pull the shift lever from the transfer case.
    8.  

  15. Raise and safely support the vehicle with jackstands at the front and rear of the vehicle. Remove the front wheels.
  16.  
  17. Drain the transmission and transfer case fluid.
  18.  
  19. Remove the oil level gauge and the tube.
  20.  
  21. Disconnect the shift select control link rod from the select lever.
  22.  
  23. Disconnect the downshift cable from the transmission.
  24.  
  25. Disconnect and plug the fluid coolant lines from the transmission.
  26.  
  27. If equipped with a 1-piece driveshaft, remove the driveshaft flange-to-pinion nuts, lower the driveshaft and pull it from the transmission.
  28.  
  29. If equipped with a 2-piece driveshaft, perform the following procedures:
  30.  
    1. Remove the rear driveshaft flange-to-pinion nuts.
    2.  
    3. Remove the rear driveshaft flange-to-front driveshaft flange bolts and the rear driveshaft.
    4.  
    5. Remove the center bearing-to-chassis bolts, move the front driveshaft rearward and from the transmission.
    6.  

  31. Remove the front driveshaft's splined yoke flange-to-transfer case bolts and separate the front driveshaft from the transfer case; do not allow the splined flange to fall away from the driveshaft.
  32.  
  33. Remove the starter-to-engine bolts and the starter.
  34.  
  35. Remove the exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts and the front exhaust pipe from the vehicle.
  36.  
  37. Attach an engine hanger to the rear of the exhaust manifold.
  38.  
  39. Using an engine hoist, connect it to the engine hangers and support the engine.
  40.  
  41. If equipped with a 2.8L engine, remove the catalytic converter and the parking brake cable bracket.
  42.  
  43. Using a transmission jack, place it under the transmission and support the assembly.
  44.  
  45. Remove the rear mount-to-transmission nuts.
  46.  
  47. Remove the rear mount-to-side mount member nuts/bolts and the mount.
  48.  
  49. Remove the transmission-to-engine bolts.
  50.  
  51. Move the transmission assembly rearward.
  52.  
  53. Carefully lower the transmission.
  54.  

To install:

  1. Raise the transmission into position.
  2.  
  3. Move the transmission forward and engage it with the engine.
  4.  
  5. Install the engine-to-transmission bolts.
  6.  
  7. Install the rear mount and the rear mount-to-side mount member nuts/bolts.
  8.  
  9. Install the rear mount-to-transmission nuts.
  10.  
  11. Remove the transmission jack.
  12.  
  13. If equipped with a 2.8L engine, install the catalytic converter and the parking brake cable bracket.
  14.  
  15. Remove the engine hoist and the engine hanger from the rear of the exhaust manifold.
  16.  
  17. Install the front exhaust pipe, exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts.
  18.  
  19. Install the starter and the starter-to-engine bolts.
  20.  
  21. Install the front driveshaft's splined yoke flange-to-transfer case bolts.
  22.  
  23. If equipped with a 2-piece driveshaft, perform the following procedures:
  24.  
    1. Install the front driveshaft into the transmission and the center bearing-to-chassis bolts.
    2.  
    3. Install the rear driveshaft and the rear driveshaft flange-to-front driveshaft flange bolts.
    4.  
    5. Install the rear driveshaft flange-to-pinion nuts.
    6.  

  25. If equipped with a 1-piece driveshaft, install the driveshaft into the transmission and the driveshaft flange-to-pinion nuts.
  26.  
  27. Connect the fluid coolant lines to the transmission.
  28.  
  29. Connect the downshift cable to the transmission.
  30.  
  31. Connect the shift select control link rod to the select lever.
  32.  
  33. Install the oil level gauge and the tube.
  34.  
  35. Install the front wheels and lower the vehicle.
  36.  
  37. Install the transfer shift lever by performing the following procedures:
  38.  
    1. Position the shift lever into the transfer case.
    2.  
    3. Install the shift lever retaining bolts.
    4.  
    5. Push the dust cover and the shift lever boot downward.
    6.  

  39. Install the gear shift lever by performing the following procedures:
  40.  
    1. Install the shift lever and the shift lever cover bolts.
    2.  
    3. Push the grommet and shift lever boot downward.
    4.  
    5. Install the front console to the floor panel.
    6.  

  41. Install the back-up light switch connector and the speedometer cable to the transmission.
  42.  
  43. Connect the necessary hoses and electrical connectors.
  44.  
  45. Install the air cleaner (4ZD1) or air cleaner duct and hose (4ZE1).
  46.  
  47. Refill the transmission and the transfer case. Install the undercover, if equipped.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Run the engine until it reaches normal temperature. Run the transmission through all gears and recheck fluid. Make sure the vehicle is supported safely and DO NOT overfill the transmission.
  52.  

 
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