Transmission Assembly: Removal

NOTE: Before removing transmission and transfer assembly from vehicle, change the transfer mode to 2WD using push button on dash panel. (V6, 4x4)

Disconnect battery ground cable.
Remove transfer protector (4X4) and fairing plate (V6).

Fig 1: Removing Transfer Protector (4X4) & Fairing Plate (V6)
Courtesy of ISUZU MOTOR CO.
Remove rear propeller shaft and front propeller shaft (4X4).
NOTE: Apply alignment marks on the flange at both front and rear sides.

Fig 2: Apply Alignment Marks On Flange (Both Front & Rear Sides - 4X4)
Courtesy of ISUZU MOTOR CO.

Fig 3: Apply Alignment Marks On Flange (Both Front & Rear Sides - 4X4)
Courtesy of ISUZU MOTOR CO.
Remove center exhaust pipe (V6, 4X4).

Fig 4: Removing Center Exhaust Pipe (V6, 4X4)
Courtesy of ISUZU MOTOR CO.
Remove fuel pipe heat protector and clip.
Disconnect fuel pipe bracket from third crossmember.

Fig 5: Removing Fuel Pipe Heat Protector & Clip
Courtesy of ISUZU MOTOR CO.

Fig 6: Disconnecting Fuel Pipe Bracket From Third Crossmember
Courtesy of ISUZU MOTOR CO.

Fig 7: Disconnecting Fuel Pipe Bracket From Third Crossmember (V6, 4X4)
Courtesy of ISUZU MOTOR CO.

Fig 8: Disconnecting Fuel Pipe Bracket From Third Crossmember (V6, 4X2)
Courtesy of ISUZU MOTOR CO.

Fig 9: Disconnecting Fuel Pipe Bracket From Third Crossmember (HEC - 1 Of 2)
Courtesy of ISUZU MOTOR CO.

Fig 10: Disconnecting Fuel Pipe Bracket From Third Crossmember (HEC - 2 Of 2)
Courtesy of ISUZU MOTOR CO.

Fuel hose connector removal procedure:

If removal of the fuel hose connector is required for transmission servicing and/or replacement, follow the steps below.

Fig 11: Removing Fuel Hose Connector
Courtesy of ISUZU MOTOR CO.
NOTE:
- An O-ring is used as a seal between the fuel pipe and the connector. Take care not to damage the contact surfaces during the removal procedure. do not allow the surfaces to become contaminated with dirt or other foreign material.
- Perform the entire removal procedure with your hands. Do not use tools.
Separating the connector and fuel pipe:
1. Clean the fuel pipe and connector to remove mud and other dirt.
2. Pull the black plastic piece toward the connector. Hold the piece near the connector. Pull the connector from the fuel pipe.
  If the connector and fuel pipe are stuck together, jiggle the connector back and forth to loosen the connector. Do not yank the connector from the fuel pipe.
  
  Fig 12: Separating Connector & Fuel Pipe
  Courtesy of ISUZU MOTOR CO.
3. Tie a vinyl bag around the connector and fuel pipe to protect them from dirt.
  
  Fig 13: Tying Vinyl Bag Around Connector
  Courtesy of ISUZU MOTOR CO.
Joining the connector and fuel hose:
1. Remove the vinyl bags from the connector and fuel hose. Check that the contact surfaces are undamaged and free of dirt and other foreign material. Clean if necessary.
2. Align the axis of the fuel pipe and connector.
  Push the connector into the fuel pipe until a distinct click is heard.
  
  Fig 14: Pushing Connector Into Fuel Pipe
  Courtesy of ISUZU MOTOR CO.
3. Gently pull on the connector to check that it is securely latched.
  
  Fig 15: Pulling On Connector
  Courtesy of ISUZU MOTOR CO.
Disconnect transmission harness connector and clip. Connector: Adapter case, mode switch, main case, magnetic sensor, transfer switch (4X4), 2-4 actuator (4X4) and car speed sensor.
Remove harness heat protector (V6).

Fig 16: Removing Harness Heat Protector (V6)
Courtesy of ISUZU MOTOR CO.
Support transmission with a jack.
Remove rear mount nuts from 3rd crossmember.

Fig 17: Removing Rear Mount Nuts From 3rd Crossmember
Courtesy of ISUZU MOTOR CO.

Fig 18: Removing Rear Mount Nuts From 3rd Crossmember (4X2)
Courtesy of ISUZU MOTOR CO.
Remove third crossmember.
Disconnect transmission Oil cooler pipes from A/T side.
Remove Oil pipe clamp and bracket from the converter housing.
Loosen Oil cooler pipe clamp bolt at the engine mount side.

Fig 19: Loosening Oil Cooler Pipe Clamp Bolt (V6, 4X4)
Courtesy of ISUZU MOTOR CO.

Fig 20: Loosening Oil Cooler Pipe Clamp Bolt (HEC)
Courtesy of ISUZU MOTOR CO.
Remove select cable by disconnecting inner cable from select lever and removing outer cable with bracket.

Fig 21: Removing Select Cable & Outer Cable With Bracket
Courtesy of ISUZU MOTOR CO.
Remove starter (V6).
Remove under covers from the transmission and engine.

Fig 22: Removing Under Covers From Transmission & Engine (HEC)
Courtesy of ISUZU MOTOR CO.
Remove transfer control lever fixing bolts and push up transfer control lever (V6, 4x4).

Fig 23: Removing Transfer Control Lever Fixing Bolts
Courtesy of ISUZU MOTOR CO.
Remove flex plate torque converter fixing bolts (6 pieces) by turning crankshaft.

Fig 24: Removing Flex Plate Torque Converter Fixing Bolts (V6)
Courtesy of ISUZU MOTOR CO.

Fig 25: Removing Flex Plate Torque Converter Fixing Bolts (HEC)
Courtesy of ISUZU MOTOR CO.
Remove engine transmission fixing bolts.
Remove exhaust pipe bracket from converter housing and exhaust pipe.

Fig 26: Removing Exhaust Pipe Bracket From Converter Housing & Exhaust Pipe
Courtesy of ISUZU MOTOR CO.
Pull out transmission from the engine.
Remove the rear mount rubber and propeller protector assembly if required (4x2).