Major Components (3): Disassembly

Remove seven bolts fixing the oil pump to the transmission case.
Remove the oil pump.

Fig 1: Removing Oil Pump
Courtesy of ISUZU MOTOR CO.
Remove race from oil pump.

Fig 2: Removing Race From Oil Pump
Courtesy of ISUZU MOTOR CO.
Remove the overdrive planetary gear and overdrive direct clutch with thrust needle bearing from the transmission case.

Fig 3: Removing Planetary Gear & Overdrive Direct Clutch
Courtesy of ISUZU MOTOR CO.
Remove the race from OD planetary gear.

Fig 4: Removing Race From OD Planetary Gear
Courtesy of ISUZU MOTOR CO.
Remove the overdrive planetary ring gear from the transmission case.

Fig 5: Removing Overdrive Planetary Ring Gear
Courtesy of ISUZU MOTOR CO.

Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake piston as shown in Fig 6 .

Fig 6: Placing Dial Indicator Onto Overdrive Brake Piston

Courtesy of ISUZU MOTOR CO.

Measure the stroke applying and releasing the compressed air (390 - 780 kPa or 57 -114 psi) as shown in Fig 7 .

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

If the values are nonstandard, select another flange.

AVAILABLE FLANGE SIZES

3.3mm (0.130 in)	3.8 mm (0.150 in)
3.5mm (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 7: Measuring Stroke Applying & Releasing Compressed Air

Courtesy of ISUZU MOTOR CO.

Remove the snap ring.

Fig 8: Removing Snap Ring
Courtesy of ISUZU MOTOR CO.
Remove one flange, four plates and four discs (B-0).

Fig 9: Removing One Flange, Four Plates & Four Discs (B-0)
Courtesy of ISUZU MOTOR CO.
Remove the thrust bearing and two races.

Fig 10: Removing Thrust Bearing & Two Races
Courtesy of ISUZU MOTOR CO.
Using snap ring pliers, remove the snap ring.

Fig 11: Removing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.
Remove the OD support.
- Remove two bolts fixing the overdrive support assembly to the transmission case.
  
  Fig 12: Removing Bolts Fixing Overdrive Support Assembly
  Courtesy of ISUZU MOTOR CO.
- Install two removed bolts to the OD support, and pull out the OD support assembly.
Fig 13: Removing OD Support Assembly
Courtesy of ISUZU MOTOR CO.
Remove the race from OD support.

Fig 14: Removing Race From OD Support
Courtesy of ISUZU MOTOR CO.

Check piston stroke of second coast brake (B-1)

Place a mark on the second coast brake piston rod as shown in Fig 15 .

Using feeler gauge, measure the stroke applying the compressed air (390 - 780 kPa or 57 -114 psi) as shown in Fig 16 .

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

If the values are nonstandard, replace piston rod and recheck piston stroke.

If piston stroke is nonstandard, replace brake band.

There are two piston rods.

ROD LENGTH SPECIFICATION

Rod length	78.4 mm (3.09 in)
Rod length	79.9 mm (3.15 in)

Fig 15: Identifying Rod Length

Courtesy of ISUZU MOTOR CO.

Fig 16: Identifying Brake Band

Courtesy of ISUZU MOTOR CO.

Using snap ring pliers, remove the snap ring.

Fig 17: Removing Snap Ring With Snap Ring Pliers
Courtesy of ISUZU MOTOR CO.
Applying compressed air to the oil hole, remove the second coast brake piston assembly.

Fig 18: Applying Compressed Air To Oil Hole
Courtesy of ISUZU MOTOR CO.
Remove the direct clutch and forward clutch from the transmission case.

Fig 19: Removing Direct Clutch & Forward Clutch
Courtesy of ISUZU MOTOR CO.
Remove the E-ring from the pin.
Remove the pin from the brake band.

Fig 20: Removing E-Ring From Pin
Courtesy of ISUZU MOTOR CO.
Remove the second coast brake band from the transmission case.

Fig 21: Removing Second Coast Brake Band
Courtesy of ISUZU MOTOR CO.
Remove the front planetary ring gear from the transmission case.

Fig 22: Removing Front Planetary Ring Gear
Courtesy of ISUZU MOTOR CO.
Remove the bearing and race.

Fig 23: Removing Bearing & Race
Courtesy of ISUZU MOTOR CO.
Remove the race.

Fig 24: Removing Race
Courtesy of ISUZU MOTOR CO.
Using snap ring pliers, remove the snap ring.

Fig 25: Removing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.

NOTE: Hold the output shaft to prevent it from falling. The output shaft falls when the snap ring is removed.
Remove the front planetary gear from the transmission case.

Fig 26: Removing Front Planetary Gear From Transmission Case
Courtesy of ISUZU MOTOR CO.
Remove sun gear input drum and one-way clutch.

Fig 27: Removing Sun Gear Input Drum & One-Way Clutch
Courtesy of ISUZU MOTOR CO.
Using two screwdrivers, remove the snap ring.

Fig 28: Removing Snap Ring With Screw Driver
Courtesy of ISUZU MOTOR CO.
Remove, five discs and six plates (B-2).

Fig 29: Removing Five Discs & Six Plates
Courtesy of ISUZU MOTOR CO.
Check pack clearance of first and reverse brake (B-3)
Using a feeler gauge, measure the clearance between the plate and second brake drum as shown in Fig 30 .

Clearance: 0.6-1.12 mm (0.0236 - 0.0440 in)

If the values are nonstandard, replace the discs.

Fig 30: Measuring Clearance Between Plate & Second Brake Drum With Feeler Gauge
Courtesy of ISUZU MOTOR CO.
Using snap ring pliers, remove the snap ring.

Fig 31: Removing Snap Ring With Snap Ring Plier
Courtesy of ISUZU MOTOR CO.
Remove the rear planetary gear, second brake drum and output shaft as an assembly.

Fig 32: Removing Rear Planetary Gear & Second Brake Drum
Courtesy of ISUZU MOTOR CO.
Remove the assembled thrust bearing and race from the transmission case.

Fig 33: Removing Thrust Bearing & Race

Courtesy of ISUZU MOTOR CO.