Major Components (3): Reassembly

Coat the assembled bearing and race with petroleum jelly and install it onto the transmission case.

ASSEMBLED BEARING AND RACE (REFERENCE)

Bearing and race	Diameter
Inside	39.38 mm (1.550 in)
Outside	58.10 mm (2.28 in)

Fig 1: Installing Bearing & Race

Courtesy of ISUZU MOTOR CO.

Install the rear planetary gear, second brake drum and output shaft.
- Align the teeth of the second brake drum, flanges, discs and plates as shown in Fig 2 .
  
  Fig 2: Installing Rear Planetary Gear
  Courtesy of ISUZU MOTOR CO.
- Align the splines of the transmission case and the assembled rear planetary gear, second brake drum and output shaft, indicated by "A" in Fig 3 .
Fig 3: Aligning Splines Of Transmission Case
Courtesy of ISUZU MOTOR CO.
Using snap ring pliers, install the snap ring.

Fig 4: Installing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.
Check pack clearance of first and reverse brake.
Using a thickness gauge, measure the clearance between the plate and second brake drum as shown in Fig 5 .

Clearance: 0.60 - 1.12 mm (0.0236 - 0.0440 in)

If the values are nonstandard, check for an improper installation.

Fig 5: Measuring Clearance Between Plate & Second Brake
Courtesy of ISUZU MOTOR CO.
Install second brake piston sleeve.

Fig 6: Installing Second Brake Piston Sleeve
Courtesy of ISUZU MOTOR CO.
Install one-way clutch in the transmission case.

Fig 7: Installing One-Way Clutch In Transmission Case
Courtesy of ISUZU MOTOR CO.
Install discs and plates (B-2).
Install the 2.5 mm (0.098 in) thick plate with the rounded edge side of the plate facing the disc.

Alternately install five discs and six plates (Disc first)

Fig 8: Installing Discs & Plates (B-2)
Courtesy of ISUZU MOTOR CO.
Install the snap ring.

Fig 9: Installing Snap Ring
Courtesy of ISUZU MOTOR CO.
While turning the sun gear input drum clockwise, install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.

Fig 10: Installing Sun Gear Input Drum Clockwise
Courtesy of ISUZU MOTOR CO.

Install the front planetary gear and bearing to the sun gear.

NOTE: Confirm the bearing and race is installed correctly.

BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing	35.5 mm (1.40 in)	47.7 mm (1.88 in)
Race	33.7 mm (1.33 in)	47.6 mm (1.87 in)

Fig 11: Installing Front Planetary Gear & Bearing To Sun Gear

Courtesy of ISUZU MOTOR CO.

With wooden blocks under the output shaft, stand the transmission on the output shaft.

Fig 12: Standing Transmission On Output Shaft With Wooden Blocks

Courtesy of ISUZU MOTOR CO.

Using snap ring pliers, install the snap ring.

Fig 13: Installing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.

Coat the bearing race with petroleum jelly and install it onto the front planetary gear.

BEARING RACE DIAMETER (REFERENCE)

Bearing race	Diameter
Inside	34.3 mm (1.350 in)
Outside	47.7 mm (1.882 in)

Fig 14: Installing Bearing Race Onto Front Planetary Gear

Courtesy of ISUZU MOTOR CO.

Insert the second coast brake band to the transmission case.

Fig 15: Inserting Second Coast Brake Band To Transmission Case
Courtesy of ISUZU MOTOR CO.
Install the E-ring and pin.
- Install the pin through the brake band.
  
  Fig 16: Installing Pin Through Brake Band
  Courtesy of ISUZU MOTOR CO.
- Install the E-ring to the pin.
Fig 17: Installing E-Ring To Pin
Courtesy of ISUZU MOTOR CO.

Coat the bearing and race with petroleum jelly and install them onto the forward clutch.

BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing	26.0 mm (1.02 in)	46.8 mm (1.84 in)
Race	25.98 mm (1.02 in)	48.87 mm (1.93 in)

Fig 18: Installing Bearing & Race Onto Forward Clutch

Courtesy of ISUZU MOTOR CO.

Coat the race with petroleum jelly and install it onto the front planetary ring gear.

RACE DIAMETER (REFERENCE)

	Inside	Outside
Race	26.8 mm (1.06 in)	47.02 mm (1.85 in)

Fig 19: Installing Race Onto Front Planetary Ring Gear

Courtesy of ISUZU MOTOR CO.

Align the flukes of the discs in the forward clutch.

Fig 20: Aligning Flukes Of Discs In Forward Clutch

Courtesy of ISUZU MOTOR CO.

Align the spline of the front planetary gear with the flukes of the discs and install the front planetary gear to the forward clutch.

Fig 21: Aligning Spline Of Front Planetary Gear
Courtesy of ISUZU MOTOR CO.

Coat the bearing and race with petroleum jelly and install them onto the ring gear.

BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing	35.2 mm (1.39 in)	53.63 mm (2.11 in)
Race	34.3 mm (1.35 in)	47.7 mm (1.88 in)

Fig 22: Installing Bearing & Race Onto Ring Gear

Courtesy of ISUZU MOTOR CO.

Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission case.

Fig 23: Installing Assembled Direct Clutch

Courtesy of ISUZU MOTOR CO.

Using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum as shown in Fig 24 .
Height: 2.5- 4.5 mm (0.098 - 0.177 in)

If the values are nonstandard, check for an improper installation.

Fig 24: Measuring Distance Between Sun Gear Input Drum & Direct Clutch Drum
Courtesy of ISUZU MOTOR CO.

Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.

ASSEMBLED BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing and race	33.7 mm (1.33 in)	47.6 mm (1.87 in)

Fig 25: Installing Assembled Bearing & Race Onto Forward Clutch

Courtesy of ISUZU MOTOR CO.

Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the second coast brake piston.

Install the washer, spring and piston to the piston rod. Install the E-ring.

Fig 26: Installing E-Ring
Courtesy of ISUZU MOTOR CO.
Coat two new oil seals with ATF and install them to the piston cover.
Install the spring, second coast brake piston assembly and piston cover to the transmission case.

Using snap ring pliers, install the snap ring.

Fig 27: Installing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.
Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod as shown in Fig 28 .

Fig 28: Placing Mark On Second Coast Brake Piston Rod
Courtesy of ISUZU MOTOR CO.

Using wire gauge, measure the stroke by applying the compressed air (390 - 780 kPa or 57 - 114 psi) as shown in Fig 29 .

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in)

If the values are nonstandard, check for an improper installation.

Fig 29: Measuring Stroke Applying Compressed Air
Courtesy of ISUZU MOTOR CO.

Coat the race with petroleum jelly and install it onto the overdrive support assembly.

RACE DIAMETER (REFERENCE)

	Inside	Outside
Race	36.8 mm (1.5 in)	50.9 mm (2.00 in)

Fig 30: Installing Race Onto Overdrive Support Assembly

Courtesy of ISUZU MOTOR CO.

Aim the bolt and oil holes of the overdrive support toward the valve hole side, and align them with the bolt hole of the transmission case and insert the overdrive support.

Fig 31: Inserting Overdrive Support
Courtesy of ISUZU MOTOR CO.
Using snap ring pliers, install the snap ring as shown in Fig 32 .

Fig 32: Installing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.
- Install and tighten the two bolts.
Torque: 25 N.m (19 lb ft)

Fig 33: Tightening Two Bolts
Courtesy of ISUZU MOTOR CO.
Check end of output shaft.
Using a dial indicator, measure the end play of the output shaft by hand.

End play: 0.27 - 0.86 mm (0.0106 - 0.0339 in)

Fig 34: Measuring End Play Of Output Shaft By Hand
Courtesy of ISUZU MOTOR CO.
Install the (flat ring) 4.0 mm (0.157 in) thick flange with the rounded edge side of the flange facing the disc.
Alternately install four discs and four plates. (Disc first)

Fig 35: Installing Flange With Rounded Edge Side Of Flange Facing Disc
Courtesy of ISUZU MOTOR CO.
Install the (stepped ring) flange with the flat side of the flange facing the disc.
Install the snap ring.
SNAP RING (REFERENCE)

Inside diameter 167.9 mm (6.61 in)

Fig 36: Installing Flange With Flat Side Of Flange Facing
Courtesy of ISUZU MOTOR CO.

Check piston stroke of overdrive brake.

Place a dial indicator onto the overdrive brake piston as shown in Fig 37 .

Fig 37: Placing Dial Indicator Onto Overdrive Brake Piston

Courtesy of ISUZU MOTOR CO.

Measure the stroke by applying and releasing the compressed air (390 - 780 kPa or 57 -114 psi) as shown in Fig 38 .

Piston stroke: 1.40 - 1.70 mm (0.0551 - 0.0669 in)

If the values are nonstandard, check for an improper installation.

AVAILABLE FLANGE SIZE

3.3 mm (0.130 in)	3.8 mm (0.150 in)
3.5 mm (0.138 in)	3.9 mm (0.154 in)
3.6 mm (0.142 in)	4.0 mm (0.158 in)
3.7 mm (0.146 in)

Fig 38: Measuring Stroke Applying & Releasing Compressed Air

Courtesy of ISUZU MOTOR CO.

Remove the snap ring.

Fig 39: Removing Snap Ring

Courtesy of ISUZU MOTOR CO.

Remove one flange, four plates and four discs.

Fig 40: Removing One Flange, Four Plates & Four Discs

Courtesy of ISUZU MOTOR CO.

Coat the bearing and races with petroleum jelly and install them onto the overdrive support.

BEARING AND RACES DIAMETER (REFERENCE)

	Inside	Outside
Race (Front)	37.2 mm (1.46 in)	58.8 mm (2.31 in)
Bearing and race (Rear)	33.8 mm (1.33 in)	50.0 mm (1.97 in)

Fig 41: Installing Bearing & Races Onto Overdrive Support

Courtesy of ISUZU MOTOR CO.

Install the overdrive planetary ring gear.

Fig 42: Installing Overdrive Planetary Ring Gear
Courtesy of ISUZU MOTOR CO.

Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.

BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing and race	31.525 mm (1.24 in)	49.145 mm (1.94 in)

Fig 43: Installing Bearing & Race Onto Planetary Ring Gear

Courtesy of ISUZU MOTOR CO.

Install the (flat ring) 4.0 mm (0.157 in) thick flange with the rounded edge side of the flange facing the disc.

Alternately install four discs and three plates. (Disc first)

Install the (stepped ring) flange with the flat side of the flange facing the disc.

Install the snap ring.

Coat the race with petroleum jelly and install it onto the planetary gear.

RACE DIAMETER (REFERENCE)

	Inside	Outside
Race	33.125 mm (1.30 in)	50.15 mm (1.97 in)

Fig 44: Installing Race Onto Planetary Gear

Courtesy of ISUZU MOTOR CO.

Install the overdrive planetary gear and direct clutch.

Fig 45: Installing Overdrive Planetary Gear & Direct Clutch
Courtesy of ISUZU MOTOR CO.

Coat the assembled bearing and race with petroleum jelly and install it onto the direct clutch.

BEARING AND RACE DIAMETER (REFERENCE)

	Inside	Outside
Bearing and race	29.2 mm (1.14 in)	50.2 mm (1.98 in)

Fig 46: Installing Assembled Bearing & Race Onto Direct Clutch

Courtesy of ISUZU MOTOR CO.

Coat the race with petroleum jelly and install it onto the oil pump.

RACE DIAMETER (REFERENCE)

	Inside	Outside
Race	28.45 mm (1.12 in)	47.4 mm (1.87 in)

Fig 47: Installing Race Onto Oil Pump

Courtesy of ISUZU MOTOR CO.

Coat the O-ring with ATF and install it around the pump body.
Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.

Install the seven bolts.

Torque: 22 N.m (16 lb ft)
Check input shaft rotation.
Make sure the input shaft rotates smoothly.

Fig 48: Checking Input Shaft Rotation
Courtesy of ISUZU MOTOR CO.