Isuzu Cars and Trucks 1981-1991

Transmission

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REMOVAL AND INSTALLATION
RWD I-Mark and 2WD P'up
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drain plug and drain the oil.
  4.  
  5. Remove the console, boot and shift lever.
  6.  
  7. Remove the starter and speedometer cable.
  8.  
  9. For a Pick-Up, remove the center bearing retainer bolts.
  10.  
  11. Mark the driveshaft flanges and remove the driveshaft.
  12.  
  13. Remove the clutch cable and flywheel stone guard.
  14.  
  15. Remove the frame-to-transmission mount bolts.
  16.  
  17. Position a jack under the transmission and remove the engine-to-transmission bolts. Turn the transmission 90and#x00B0; clockwise for easier removal.
  18.  

To install:

  1. Using a transmission jack, position the transmission-to-engine and torque the retaining bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the frame-to-rear housing mount bolts and tighten.
  4.  
  5. Install the flywheel stone guard and clutch cable.
  6.  
  7. Install the driveshaft to the mark position. For the Pick-Up, torque the center bearing bolts to 46 ft. lbs. (65 Nm). Position the retaining bolts with the head facing rearward and torque to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the speedometer cable, starter motor, shift lever and boot.
  10.  
  11. Install the drain plug and refill the transmission with 30 SAE engine oil.
  12.  

RWD Impulse
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the slave cylinder.
  6.  
  7. Disconnect the back-up light switch and speedometer cable.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the gear shift boot, console and shift lever.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the transmission drain plug and drain the oil.
  16.  
  17. Mark the driveshaft flanges and remove the driveshaft, starter motor, exhaust pipe and hanger.
  18.  
  19. Support the transmission with a jack.
  20.  
  21. Remove the rear transmission mount from the crossmember.
  22.  
  23. Remove the shift quadrant box.
  24.  
  25. Remove the transmission-to-engine bolts.
  26.  
  27. Manually move the transmission as far as possible toward the rear of the vehicle, above the crossmember. Lower the clutch housing end while the rear of the transmission is supported by the crossmember. Lower the transmission jack after the clutch housing has cleared the engine.
  28.  

To install:

  1. Apply axle grease to the top gear shaft spline.
  2.  
  3. Place the transmission on a jack and move into position behind the engine.
  4.  
  5. Raise the jack until the rear of the transmission can be rested on the rear crossmember. Raise the clutch housing and align the top shaft splines with the clutch assembly. Move the transmission into position.
  6.  


NOTE
The engine may have to be raised to allow the engine and transmission to be at the same angle.

  1. Install the engine-to-transmission bolts and torque to 28 ft. lbs. (37 Nm).
  2.  
  3. Install the rear mount-to-crossmember, starter motor, exhaust pipe and bracket.
  4.  
  5. Install the driveshaft as previously marked and torque the bolts to 26 ft. lbs. (37 Nm). Torque the center bearing bolts to 45 ft. lbs. (61 Nm).
  6.  
  7. Install the gear shift lever, boot, console and refill the transmission with SAE 30 weight engine oil.
  8.  
  9. Lower the vehicle and connect the negative battery cable.
  10.  

Early 4WD P'up and Trooper
  1. Disconnect the negative battery cable, raise and safely support the vehicle and drain the transmission fluid.
  2.  
  3. Remove the shift lever boots, shift lever and quadrant box.
  4.  
  5. Remove the starter, speedometer cable and center bearing.
  6.  
  7. Mark the driveshaft-to-differential flanges and remove the front and rears driveshafts.
  8.  
  9. Disconnect the clutch cable.
  10.  
  11. Remove the flywheel stone guard, transfer side case and transmission frame member.
  12.  
  13. Install a transmission jack and remove the mount bolts and nuts.
  14.  
  15. Remove the transmission-to-engine bolts, turn the transmission assembly 90and#x00B0; clockwise to ease removal.
  16.  

To install:

  1. Using a transmission jack, position the transmission to the engine and clutch assembly. Torque the retaining bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Install the frame-to-rear housing mount bolts and tighten.
  4.  
  5. Install the transmission-to-transfer side case. Align the grooves in the shift arms and shift sleeves while held in the 2H position. Torque the retaining bolts to 34 ft. lbs. (46 Nm).
  6.  
  7. Install the flywheel stone guard and clutch cable.
  8.  
  9. Install the driveshafts to the mark position. Torque the center bearing bolts to 46 ft. lbs. (65 Nm). Position the retaining bolts with the head facing rearward and torque to 22 ft. lbs. (30 Nm).
  10.  
  11. Install the speedometer cable, starter motor, shift levers and boots.
  12.  
  13. Install the drain plug and refill the transmission with 30 SAE engine oil. Torque the fill plug to 25 ft. lbs. (34 Nm).
  14.  

Late 4WD P'up, Amigo and Trooper
  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 driveshaft-to-differential flanges and remove the front and rear driveshafts.
  8.  
  9. Leave the clutch slave cylinder fluid hose connect and remove the cylinder from the transmission and attach out of the way.
  10.  
  11. Remove the transmission-to-engine bolts. Install a jack and slightly raise the transmission.
  12.  
  13. Remove the crossmember and transmission mount. Support the engine with a jackstand.
  14.  
  15. With an assistant, remove the transmission/transfer case as an assembly.
  16.  

To install:

  1. With an assistant, install the transmission-to-engine. Make sure the input shaft is splined properly into 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.  

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 of 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.  

 
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