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Transmission Reassembly

  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 faces 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. See Fig 1.
    Fig 1: Installing Planetary Assembly Snap Ring
    G96J15031Courtesy of ISUZU MOTOR CO.
  5. Check operation of No. 3 brake piston by applying low pressure compressed air to oil holes. See Fig 7. Audible "plop" noise should be heard.
    Fig 2: Locations of Thrust Bearings (55, 70, 71 & 75)
    G96A15032Courtesy of ISUZU MOTOR CO.
    Fig 3: Locations of Thrust Bearings (7OL & 72L)
    G96B15033Courtesy 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. DO NOT  tighten bolts at this time.
  7. Aligning discs on center support, 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. Aligning discs, install forward (front) clutch in case, engaging lugs of direct (rear) clutch to grooves in hub of forward (front) clutch.
  9. Install bearing and race on input shaft, with race toward oil pump. Position oil pump in case. Install and tighten attaching bolts. Tighten bolts alternately and evenly. Avoid damaging or warping "O" rings.
  10. Starting with bolt next to accumulator piston bores, tighten center support bolts in 4 steps. Check operation of brake and clutch pistons with low pressure compressed air. See Fig 7. As 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. Zero dial indicator. Move input shaft up and down. Note maximum dial indicator reading. This reading is input shaft end play. End play should be and .012-.035" (.30-.90 mm). Input shaft should rotate without binding.
  12. Attach torque converter housing to transmission case. Tighten 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. Install pistons into bores.
  13. Connect throttle cable to throttle cam on valve body. Install valve body assembly with selector cam pin fitted in manual valve recess. Install and tighten valve body attaching bolts. See Fig 4 to 35. Install strainer on valve body. Tighten bolts. Install particle magnet, oil pan gasket and oil pan. Install and tighten bolts.
    Fig 4: Valve Body Attaching Bolt I.D. & Location (1 of 3) (Numbers denote screw length in millimeters (mm))
    G96C15034Courtesy of ISUZU MOTOR CO.
    Fig 5: Valve Body Attaching Bolt I.D. & Location (2 of 3) (Numbers denote screw length in millimeters (mm))
    G96D15035Courtesy of ISUZU MOTOR CO.
    Fig 6: Valve Body Attaching Bolt I.D. & Location (3 of 3) (Numbers denote screw length in millimeters (mm))
    G96E15036Courtesy of ISUZU MOTOR CO.
  14. Align governor retaining clip with hole in output shaft. Slide governor onto shaft. Engage clip into 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. Using Loctite, install flange nut on output shaft threads. Hold drive flange stationary while tightening flange nut. Install speedometer driven gear into transmission case bore. Install retainer plate. Tighten bolt.
  16. Position torque converter on input shaft. Turning converter slowly, slide it onto input shaft splines and oil pump drive. Place straightedge across converter housing. Measure distance from straightedge to converter face ring. Measurement should be and 1.24" (31.5 mm) for AW 55 transmissions.
Fig 7: Checking Clutch & Brake Piston Operation
G96F15037Courtesy of ISUZU MOTOR CO.
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