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Home › Isuzu › 2004 › Rodeo 3.2 W, 4WD, Standard › Repair and Diagnosis › Transmission › Manual Transmission › Transmission › Installation

Manual Transmission: Transmission: Installation

  1. Apply grease (BESCO L2 or equivalent) on the splined portion of the output shaft.
  2. Connect the transfer to the transmission.
  3. Install the transmission-transfer bolts and nut and tighten them to the specified torque.

    Torque:  41 N.m (30 lb ft)

    Fig 1: Tightening Transmission-Transfer Bolts & Nut
    G02794073Courtesy of ISUZU MOTOR CO.
  4. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
  5. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine.

    The slope of the engine and the transmission must be the same.

  6. Align the top gear shaft spline with the clutch driven plate spline.
    Fig 2: Aligning Top Gear Shaft Spline With Clutch Driven Plate Spline
    G02794074Courtesy of ISUZU MOTOR CO.
  7. Install the transmission to the engine.

    Tighten the transmission nuts and bolts as shown in Fig 3 for 6VD1 or Fig 4 for Y22SE engine. .

    Fig 3: Installing Transmission To Engine (6VD1)
    G02794075Courtesy of ISUZU MOTOR CO.
    Fig 4: Installing Transmission To Engine (Y22SE)
    G02794076Courtesy of ISUZU MOTOR CO.
  8. Apply a force of 59 - 78 N (13.2 - 17.6 lb) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing.
    NOTE: A click sound is heard when the release bearing and the tip of the diaphragm spring engage each other.
    Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine side while applying a force of about 25 N (5.5 lb). If the shift fork will not move, then they are securely engaged.
    Fig 5: Applying Force To Tip Of Shift Fork
    G02795521Courtesy of ISUZU MOTOR CO.
  9. Install flywheel under cover (17). 6VD1 engine 3 pieces, HEC engine 1 piece.
    1. Torque:  8 N.m (69 lb in)
  10. Install starter (16).
    1. Torque:  40 N.m (30 lb ft)
  11. Install third crossmember (15).
    1. Torque:  50 N.m (37 lb ft)
  12. Install engine rear mount nuts (14).
    1. Torque:  40 N.m (30 lb ft)

    Remove the transmission jack from transmission side.

  13. Apply grease to top hole portion of the shift fork.

    Install slave cylinder (12) and flexible hose fixing bracket (Y22SE engine).

    Torque:  43 N.m (32 lb ft)

    Fig 6: Applying Grease To Top Hole Portion Of Shift Fork
    G02794074Courtesy of ISUZU MOTOR CO.
  14. Install clutch dust covers (13) to clutch housing (6VD1 Engine).
    1. Torque:  6 N.m (52 lb in)
  15. Connect transmission harness connectors and clip.

    Connector: Neutral switch: Transmission, Backup switch, Car speed sensor, Actuator (4x4), 2WD-4WD switch (4x4), Neutral switch: Transfer (4x4).

  16. Install bracket and transmission harness clamps (12) to the transmission case.
  17. Install harness heat protector (11) (6VD1 Engine).
  18. Connect fuel pipe to transmission side.
    Fig 7: Connecting Fuel Pipe To Transmission Side (1 Of 2)
    G02795523Courtesy of ISUZU MOTOR CO.
    Fig 8: Connecting Fuel Pipe To Transmission Side (2 Of 2)
    G02795524Courtesy of ISUZU MOTOR CO.
  19. Install fuel pipe heat protector (9) and clip.
    Fig 9: Installing Fuel Pipe Heat Protector & Clip
    G02795525Courtesy of ISUZU MOTOR CO.
  20. Install center exhaust pipe (8) (6VD1 Engine).
    1. Torque:  43 N.m (32 lb ft)
    Fig 10: Installing Center Exhaust Pipe (6VD1 Engine)
    G02795526Courtesy of ISUZU MOTOR CO.
  21. Install front (7) (4X4) and rear propeller shaft (6).
    1. Torque:  59 N.m (43 lb ft)
  22. Install fairing plate (5). Lower the vehicle.
    Fig 11: Installing Fairing Plate
    G02795527Courtesy of ISUZU MOTOR CO.
  23. Install gear control lever (4).
  24. Install grommet assembly (3).
  25. Install center console (2), rear console and lower cluster assembly.
  26. Install gear control lever knob (1).
  27. Connect battery ground cable.
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