Isuzu_Rodeo_Rodeo_Sport_1997-2004

Transmission Removal & Installation

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1997-03 Models



2 Wheel Drive

NOTE
The transmission flange bolts vary in length. Note their locations for assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the hood.
  4.  
  5. Install a support fixture to the engine lifting eyes.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever knob
     
    Rear console assembly
     
    Grommet assembly
     
    Shift lever
     
    Clutch slave cylinder and hose bracket
     
    Driveshaft
     
    Fuel line heat shield
     
    Vehicle Speed (VSS) sensor connector
     
    Reverse light switch connector
     
    Flywheel under cover
     
    Transmission mount and crossmember
     
    Transmission flange bolts
     
    Transmission
     

  8.  

To install:

Click image to see an enlarged view

Fig. Transmission flange bolt identification and torque-2 wheel drive transmission

  1. Install or connect the following:

    Transmission. Tighten the large flange bolts to 52 ft. lbs. (71 Nm) and the small bolts to 30 ft. lbs. (41 Nm).
     
    Crossmember. Tighten the bolts to 56 ft. lbs. (76 Nm).
     
    Transmission mount. Tighten the fasteners to 30 ft. lbs. (41 Nm).
     
    Flywheel under cover. Tighten the bolts to 69 inch lbs. (8 Nm).
     
    Reverse light switch connector
     
    Vehicle Speed (VSS) sensor connector
     
    Fuel line heat shield
     
    Driveshaft. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Clutch slave cylinder and hose bracket
     
    Shift lever
     
    Grommet assembly
     
    Rear console assembly
     
    Shift lever knob
     
    Negative battery cable
     

  2.  
  3. Remove the engine support fixture and install the hood.
  4.  

4 Wheel Drive

NOTE
The transmission flange bolts vary in length. Note their locations for assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the hood.
  4.  
  5. Install a support fixture to the engine lifting eyes.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever knob
     
    Console assembly
     
    Grommet assembly
     
    Shift lever
     
    Transfer case control lever
     
    Transfer case skid plate
     
    Front and rear driveshafts
     
    Reverse lamp switch connector
     
    Indicator switch connectors
     
    Vehicle Speed (VSS) sensor connector
     
    4WD actuator connector
     
    Transmission harness clamps
     
    Fuel pipe bracket
     
    Clutch slave cylinder and heat shield
     
    Transmission mount and crossmember
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Right exhaust front pipe
     
    Wiring harness heat shield
     
    Flywheel under cover
     

  8.  
  9. Release the throw out bearing from the pressure plate as shown.
  10.  
  11. Remove the transmission flange bolts and remove the transmission.

    Click image to see an enlarged view

    Fig. Insert the tool between the wedge collar and the release bearing



    Click image to see an enlarged view

    Fig. Turn the remover to separate the release bearing

  12.  

To install:

Click image to see an enlarged view

Fig. Insert the Release Bearing Remover tool J-39207 through the bell housing-4 wheel drive manual transmission



Click image to see an enlarged view

Fig. Push the release bearing fork toward the transmission to release the bearing from the pressure plate-4 wheel drive manual transmission



Click image to see an enlarged view

Fig. Transmission mounting bolt identification and torque specifications-V6 engine with 4 wheel drive transmission shown

  1. Install the transmission. Tighten the large bolts to 56 ft. lbs. (76 Nm) and the small bolts to 52 inch lbs. (6 Nm).
  2.  
  3. Apply 13-18 lbs. (59-78 N) of force to the clutch fork to engage the throw out bearing to the pressure plate.

    Click image to see an enlarged view

    Fig. Push the release bearing fork toward the transmission to engage the release bearing with the pressure plate

  4.  
  5. Install or connect the following:

    Flywheel under cover
     
    Wiring harness heat shield
     
    Right exhaust front pipe. Tighten the manifold flange fasteners to 49 ft. lbs. (67 Nm) and the exhaust flange bolts to 32 ft. lbs. (43 Nm).
     
    HO 2 S sensor connectors
     
    Crossmember. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Transmission mount. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    Clutch slave cylinder and heat shield
     
    Fuel pipe bracket
     
    Transmission harness clamps
     
    4WD actuator connector
     
    VSS sensor connector
     
    Indicator switch connectors
     
    Reverse lamp switch connector
     
    Front and rear driveshafts. Tighten the flange bolts to 46 ft. lbs. (63 Nm).
     
    Transfer case skid plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Transfer case control lever
     
    Shift lever
     
    Grommet assembly
     
    Console assembly
     
    Shift lever knob
     
    Negative battery cable
     

  6.  
  7. Remove the engine support fixture and install the hood.

    Click image to see an enlarged view

    Fig. Dowel pin locations for automatic and manual transmissions-3.2L engine

  8.  

2004 Models




NOTE
The transmission flange bolts vary in length. Note their locations for assembly.

  1. For 4x4 models, turn the transfer case selector knob to 2WD.
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever knob
     
    Lower cluster
     
    Rear console
     
    Center console assembly
     
    Grommet assembly
     
    Shift lever
     

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove or disconnect the following:

    Transfer case skid plate
     
    Front and rear driveshafts. Matchmark the flanges for installation.
     
    Center exhaust pipe
     
    Transfer case control lever
     
    Reverse lamp switch connector
     
    Indicator switch connectors
     
    Vehicle Speed (VSS) sensor connector
     
    4WD actuator connector
     
    Transmission harness clamps
     
    Fuel pipe heat shield
     
    Wiring harness heat shield
     
    Clutch slave cylinder and heat shield
     
    Dust covers
     

  10.  
  11. Support the transmission with a jack.
  12.  
  13. Remove the engine rear mount nuts.
  14.  
  15. Remove the 6 bolts and the 3rd crossmember.
  16.  
  17. Remove the starter.
  18.  
  19. Remove the flywheel covers.
  20.  
  21. Release the throw out bearing from the pressure plate as shown.

    Click image to see an enlarged view

    Fig. Use tool J-392007 to disconnect the release bearing from the pressure plate



    Click image to see an enlarged view

    Fig. Pull the shift fork towards the transmission. Install the tool between the release bearing and the wedge collar



    Click image to see an enlarged view

    Fig. Turn the tool to separate the release bearing

  22.  
  23. Remove the transmission flange bolts and remove the transmission and transfer case.
  24.  

To install:

  1. Apply chassis lube to the splines of the input shaft.
  2.  
  3. Connect the transfer case to the transmission. Torque the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Slowly raise the assembly into position. Install the transmission. Tighten the bolts as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Transmission installation nut and bolt torques-2004 manual transmission

  6.  
  7. Apply 13-18 lbs. (59-78 N) of force to the clutch fork to engage the throw out bearing to the pressure plate. A click will be heard when they engage.
  8.  
  9. Install or connect the following:

    Flywheel under cover
     
    Starter
     
    Crossmember. Torque to 37 ft. lbs. (50 Nm)
     
    Transmission mount. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    Clutch slave cylinder and heat shield. Torque to 32 ft. lbs. (43 Nm).
     
    Dust covers
     
    Transmission harness clamps
     
    Wiring harness heat shield
     
    HO 2 S sensor connectors
     
    Crossmember. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Fuel pipe bracket
     
    4WD actuator connector
     
    VSS sensor connector
     
    Indicator switch connectors
     
    Reverse lamp switch connector
     
    Fuel pipe
     
    Center exhaust. Tighten the exhaust flange bolts to 32 ft. lbs. (43 Nm).
     
    Front and rear driveshafts. Tighten the flange bolts to 43 ft. lbs. (59 Nm).
     
    Transfer case skid plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Transfer case control lever
     
    Shift lever
     
    Grommet assembly
     
    Consoles assembly
     
    Shift lever knob
     
    Negative battery cable
     

  10.  

2-Wheel Drive




NOTE
The transmission flange bolts vary in length. Note their locations for assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the hood.
  4.  
  5. Install a support fixture to the engine lifting eyes.
  6.  
  7. Remove or disconnect the following: Negative battery cableShift lever knobRear console assemblyGrommet assemblyShift leverClutch slave cylinder and hose bracketDriveshaftFuel line heat shieldVehicle Speed (VSS) sensor connectorReverse light switch connectorFlywheel under coverTransmission mount and crossmemberTransmission flange boltsTransmission

    Negative battery cable
     
    Shift lever knob
     
    Rear console assembly
     
    Grommet assembly
     
    Shift lever
     
    Clutch slave cylinder and hose bracket
     
    Driveshaft
     
    Fuel line heat shield
     
    Vehicle Speed (VSS) sensor connector
     
    Reverse light switch connector
     
    Flywheel under cover
     
    Transmission mount and crossmember
     
    Transmission flange bolts
     
    Transmission
     

  8.  

To install:



Click image to see an enlarged view

Fig. Transmission flange bolt identification and torque-2 wheel drive transmission

  1. Install or connect the following: Transmission. Tighten the large flange bolts to 52 ft. lbs. (71 Nm) and the small bolts to 30 ft. lbs. (41 Nm).Crossmember. Tighten the bolts to 56 ft. lbs. (76 Nm).Transmission mount. Tighten the fasteners to 30 ft. lbs. (41 Nm).Flywheel under cover. Tighten the bolts to 69 inch lbs. (8 Nm).Reverse light switch connectorVehicle Speed (VSS) sensor connectorFuel line heat shieldDriveshaft. Tighten the bolts to 37 ft. lbs. (50 Nm).Clutch slave cylinder and hose bracketShift leverGrommet assemblyRear console assemblyShift lever knobNegative battery cable

    Transmission. Tighten the large flange bolts to 52 ft. lbs. (71 Nm) and the small bolts to 30 ft. lbs. (41 Nm).
     
    Crossmember. Tighten the bolts to 56 ft. lbs. (76 Nm).
     
    Transmission mount. Tighten the fasteners to 30 ft. lbs. (41 Nm).
     
    Flywheel under cover. Tighten the bolts to 69 inch lbs. (8 Nm).
     
    Reverse light switch connector
     
    Vehicle Speed (VSS) sensor connector
     
    Fuel line heat shield
     
    Driveshaft. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Clutch slave cylinder and hose bracket
     
    Shift lever
     
    Grommet assembly
     
    Rear console assembly
     
    Shift lever knob
     
    Negative battery cable
     

  2.  
  3. Remove the engine support fixture and install the hood.
  4.  

4-Wheel Drive



 
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