Isuzu Cars and Trucks 1981-1991

Transmission and Transaxle

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FLUID RECOMMENDATION
Manual

Use engine oil for all the manual transmissions and transaxles, except for the Borg Warner T5R. The BW T5R uses Dexronand#x00AE;II automatic transmission fluid. The BW transmission is used in the 1991 Rodeo (4x2) with the V6 engine.



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Fig. Manual transmission and transaxle oil viscosity chart

Automatic

Use only Dexronand#x00AE;II Automatic Transmission Fluid.

FLUID LEVEL CHECK
Manual

The oil in the manual transmission should be checked every 12 months or 15,000 miles.

  1. Allow the engine to reach normal operating temperature, raise the vehicle and support with jackstands and remove the filler plug from the side of the transmission/transaxle housing. Remove the speedometer driven gear assembly to check the fluid on the front wheel drive I-Mark.
  2.  
  3. If lubricant begins to trickle out of the hole, there is enough and you need not go any further. Otherwise, carefully insert your finger (watch out for sharp threads) and check to see if the oil is up to the edge of the hole.
  4.  
  5. If not, add oil through the hole until the level is at the edge of the hole. Most engine oils come in a plastic bottle with a nozzle; making additions simple. Use a turkey baster if the area does not permit access.
  6.  
  7. Replace the filler plug or speedometer driven gear and torque to 20 ft. lbs. (27 Nm). Run the engine and check for leaks.
  8.  



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Fig. Manual transmission drain and fill plugs



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Fig. Manifold transmission/transfer case drain and fill plugs they are separate units and must be drain independently



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Fig. I-Mark (FWD) manual transaxle drain and fill refill through the speedometer gear assembly



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Fig. Impulse/Stylus (FWD) manual transaxle drain and fill plugs



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Fig. Borg Warner T5R manual transmission 1991 Rodeo (4x2), uses ONLY Dexronand#x00AE; II fluid

Automatic

Check the automatic transmission fluid level at least every 15,000 miles or 12 months. The dipstick can be found in the rear of the engine compartment. The fluid level should be checked only when the transmission is hot (normal operating temperature). The transmission is considered hot after about 20 miles of highway driving.


NOTE
If you have driven for a prolonged period of time or in city traffic in hot weather, wait until the fluid cools down, about 30 minutes before checking the fluid level.

  1. Park the car on a level surface with the engine idling. Shift the transmission into Park and set the parking brake.
  2.  
  3. Remove the dipstick, wipe it clean and then reinsert it firmly. Be sure that it has been pushed all the way in. Remove the dipstick again and check the fluid level while holding it horizontally. With the engine running, the fluid level should be between the second notch and the "FULL HOT" line. If the fluid must be checked when it is cool, the level should be between the first and second notches.
  4.  
  5. If the fluid level is below the second notch (engine hot) or the first notch (engine cold), add Dexronand#x00AE;II automatic transmission fluid through the dipstick tube. This is easily done with the aid of a funnel. Check the level often as you are filling the transmission. Be extremely careful not to overfill it. Overfilling will cause slippage, seal damage and overheating. Approximately 1 pint of ATF will raise the fluid level from one notch/line to the other.
  6.  


NOTE
Use only Dexronand#x00AE;II ATF. The use of any other fluid will cause severe damage to the transmission.

The fluid on the dipstick should always be a bright red color. If it is discolored (brown or black), or smells burnt, serious transmission troubles, probably due to overheating, should be suspected. The transmission should be inspected by a qualified technician to locate the cause of the burnt fluid.



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Fig. Automatic transaxle fluid level check



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Fig. Typical automatic transmission/transaxle dipstick



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Fig. Late model automatic transmission dipstick maintain a level between the COLD lines at 68 and 1986and#x00B0;F (20 and 1930and#x00B0;C)and the HOT lines at 158 and 19176and#x00B0;F (70 and 1980and#x00B0;C)



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Fig. Add automatic transmission fluid through the dipstick tube

DRAIN AND REFILL
Manual

NOTE
Before removing the oil from the transmission, drive the car to ensure that the oil has been warmed and the sediment has been stirred.

Replace the transmission/transaxle fluid at the first 15,000 miles and then every 30,000 miles.

  1. Raise the car and support on jack stands. Place an oil catch pan under the transmission.
  2.  
  3. Remove the plugs from the bottom and the side of the transmission. Allow the oil to drain into the pan. Remove the speedometer driven gear for the FWD I-Mark.
  4.  
  5. Refer to the "Oil Viscosity" chart for oil application. Replace the bottom plug and torque to 20 ft. lbs. (27 Nm). Install the new oil through the hole in the side of the transmission. Fill until the oil is level with the fill hole or to the level on the speedometer gear assembly. Replace the plug and lower the car.
  6.  



Click image to see an enlarged view

Fig. Manual transmission drain and fill plugs



Click image to see an enlarged view

Fig. Manifold transmission/transfer case drain and fill plugs they are separate units and must be drain independently



Click image to see an enlarged view

Fig. I-Mark (FWD) manual transaxle drain and fill refill through the speedometer gear assembly



Click image to see an enlarged view

Fig. Impulse/Stylus (FWD) manual transaxle drain and fill plugs



Click image to see an enlarged view

Fig. Borg Warner T5R manual transmission 1991 Rodeo (4x2), uses ONLY Dexronand#x00AE; II fluid

Automatic
  1. Drive the vehicle until it has reached normal operation temperature. Raise and support the car on jack stands. Place an oil catch pan under the transmission.
  2.  


NOTE
Some models have transmission oil pan drain plugs, if so remove the plug and allow the fluid to drain into the catch pan. If not, the oil pan has to be removed to drain the fluid.

  1. Remove all of the oil pan bolts, except for two corner bolts, which must be loosened 3 complete turns.
  2.  
  3. Using a rubber mallet, strike the opposite corner of the pan with one hand and hold up the oil pan with the other. Allow the fluid to drain and remove the pan. Remove the filter/screen.
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  5. Clean the oil pan and screen. Clean the mating surface of the transmission/transaxle with a scraper. Wash the mating surfaces with solvent to remove the oil film.
  6.  
  7. Install a new filter.
  8.  
  9. Install a new pan gasket, making sure it is in the proper position. Use the pan bolts to hold the gasket in place.
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  11. Raise the oil pan into position and tighten the bolts. Torque the bolts to 120 inch lbs. (10 Nm).
  12.  
  13. Add new transmission fluid through the dipstick tube. Start the engine and shift the transmission through the gear while the drive wheels are off the ground. Fill the transmission to the COLD level and check for leaks. Drive the vehicle and adjust the level to the HOT line. DO NOT overfill.
  14.  



Click image to see an enlarged view

Fig. Late model automatic transmission dipstick maintain a level between the COLD lines at 68 and 1986and#x00B0;F (20 and 1930and#x00B0;C)and the HOT lines at 158 and 19176and#x00B0;F (70 and 1980and#x00B0;C)



Click image to see an enlarged view

Fig. Add automatic transmission fluid through the dipstick tube

 
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