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Transaxle Reassembly

NOTE: Where low pressure compressed air is called for, Volvo specifies 14 psi (1 kg/cm2 ). Isuzu specifies 57-114 psi (4-8 kg/cm2 ).
  1. Install NEW oil seals for manual shaft in case. Install NEW "O" rings on oil cooler line nipples. Install nipples in transmission case so they point in same direction as when removed. Install line pressure and governor pressure plugs with new "O" rings.
  2. Install cover for governor oil ducts on transmission case. Always use new gasket. Install throttle cable in case. Assemble parking pawl, spring and shaft in case. Install detent lever and shaft, using NEW collar and pin. Drive NEW retaining pin through lever and shaft.
  3. Fit parking pawl rod to pawl and detent lever. Install parking pawl cam plate. Invert transmission case so case opening is up. Install rearmost bearing and race. Install No. 3 brake apply tube into case. Lower lugs on tube go inside No. 3 brake piston bore. Parking pawl pin fits in middle of drum recess.
  4. Install planetary gear and No. 3 brake disc assembly into transmission case with recess in reaction plate lug toward oil pan. Install planetary assembly retaining snap ring in groove of case. Snap ring ends must be between splines. Fig 1 .
    Fig 1: Installation of Planetary Assembly Snap Ring
    G00274073Courtesy of ISUZU MOTOR CO.
  5. Check operation of No. 3 brake piston by applying low pressure compressed air to oil holes. Fig 2 . When air is applied, audible "plop" noise should be heard.
    Fig 2: Checking No. 3 Brake Piston Operation
    G00274074Courtesy of ISUZU MOTOR CO.
  6. Hold sun gear shaft and lower center support assembly into transmission case until it mates with planetary gear assembly. Install center support bolts into case by hand to avoid thread damage. DO NOT  tighten bolts at this time.
  7. Align discs on center support and install direct (rear) clutch assembly into transmission case. If direct (rear) clutch is properly assembled, clutch splines and sun gear shaft splines should mesh. Position bearings and races on direct (rear) clutch hub.
  8. Align discs and install forward (front) clutch in case, engaging lugs of direct (rear) clutch to grooves in hub of forward (front) clutch. Isuzu specifies that face of correctly installed forward (front) clutch will be about .06" (1.5 mm) from face case where oil pump attaches.
  9. Install bearing and race on input shaft, with race toward oil pump. Position oil pump in case, then install and tighten attaching bolts. Tighten bolts alternately and evenly. Be careful to avoid damaging or warping of "O" rings.
  10. Tighten center support bolts in 4 steps, starting with bolt next to accumulator piston bores. Check operation of brake and clutch pistons by applying low pressure compressed air to respective oil hole. Fig 3 . When air is applied to each oil hole, distinct "plop" should be heard.
  11. Mount dial indicator on transmission case with indicator tip touching end of input shaft. Fig 3 . Zero dial indicator. Move input shaft up and down and note maximum dial indicator reading. This reading is input shaft end play. End play should be .009-.20" (.22-.53 mm) for BW 55 and .012-.035" (.30-.90 mm) for all others. Input shaft should rotate without binding.
  12. Attach torque converter housing to transmission case and tighten converter housing-to-transmission case bolts. Rotate transmission on holding fixture until oil pan mounting surface is up. Install accumulator piston springs into case bore. Install new "O" rings on accumulator pistons and install pistons into bores.
    Fig 3: Checking Clutch & Brake Piston Operation
    G96F15037Courtesy of ISUZU MOTOR CO.
    NOTE: On AW 70 and 71 transmission, No. 2 brake spring is longer than forward (front) clutch spring. On AW and BW 55 transmissions, forward (front) clutch spring is longer than No. 2 brake spring. Short spring is installed in center bore on all transmissions. Install small piston in center bore on all transmissions. Two large pistons are different sizes and cannot be incorrectly installed.
    Fig 4: Measuring Input Shaft End Play
    G00274075Courtesy of ISUZU MOTOR CO.
  13. Connect throttle cable to throttle cam on valve body. Place valve body assembly in position with selector cam pin fitted in manual valve recess. Install and tighten valve body attaching bolts. Fig 5 . Install strainer on valve body and tighten attaching bolts. Install particle magnet, oil pan gasket and oil pan. Install and tighten attaching bolts.
    Fig 5: Valve Body Attaching Bolt Identification & Location
    G00274076Courtesy of ISUZU MOTOR CO.
  14. Align governor retaining clip with hole in output shaft. Slide governor onto shaft and engage clip in hole in shaft. Slide spacer ring and speedometer drive gear onto output shaft. Position extension housing with new gasket on transmission case. Tighten attaching bolts.
  15. Install drive flange on output shaft. Use Loctite and install flange nut on output shaft threads. Hold drive flange stationary and tighten flange nut. Install speedometer driven gear into transmission case bore. Install retainer plate and tighten bolt.
  16. Position torque converter on input shaft. Turn converter slowly and slide it onto input shaft splines and oil pump drive. Place straightedge across converter housing and measure distance from converter housing surface to converter face ring. Distance should be .64-77" (16.3-19.6 mm) for BW 55 and 1.24" (31.5 mm) for AW 55 transmissions.
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