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Home >> Isuzu >> 1988 >> Trooper II Base, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - Aw30-80LE >> Transmission Reassembly

Transmission Reassembly

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts (as necessary). Clutch discs should be soaked in ATF for at least 30 minutes before installation.
  1. Coat assembled bearing and race with petroleum jelly and install on transmission case. Align teeth of 2nd brake drum, flange, discs and plates. Align splines of transmission case and assembled rear planetary gear, 2nd brake drum and output shaft. See Fig 1 .
  2. Install small ring in case with chamfered edge toward front of transmission. Ensure ends of snap ring are not aligned with cutout area of case. Measure 1st and reverse brake clearance between 2nd brake drum and plate. See Fig 3 . Standard clearance should be .0197-.0701" (.500-1.780 mm). If clearance is not within specification, check for improper installation.
  3. Install 2nd brake piston sleeve with large surface toward front of transmission. Install one-way clutch. Install .098" (2.50 mm) thick plate with rounded edge side of plate facing disc. Install discs and plates, starting with a disc and alternating with a plate. Install 4 discs and 3 plates. Install flange with rounded edge facing disc. Install snap ring.
  4. Measure 2nd brake clearance between snap ring and flange. See Fig 2 . Standard clearance should be .0197-.0693" (.500-1.760 mm). If clearance is not within specification, check for improper installation.
  5. While turning sun gear clockwise, install sun gear into one-way clutch. Ensure all thrust washers are correctly installed. Install front planetary gear to sun gear. Install front planetary gear bearing and race. With wooden blocks under output shaft, stand transmission case on output shaft. Install snap ring.
  6. Install bearing race on front planetary gear so race tabs align with planetary gear holes.
  7. Install 2nd coast brake band and pin. Pin must be installed so "E" ring is toward front of transmission. Install "E" ring. Install thrust bearing and race on forward clutch. Raised portion of race must be toward front.
  8. Install race on front planetary ring gear. Smooth flat surface must be toward front. Align disc tabs of forward clutch. Install front planetary gear in forward clutch. Ensure gear is aligned with all clutch discs.
  9. Install bearing race and thrust bearing on ring gear. Raised portion of race must be toward rear. Install forward and direct clutch assembly and front planetary ring gear in transmission case. Measure distance between sun gear input drum and direct clutch drum. See Fig 3 . Standard clearance should be .386-.465" (9.80-11.81 mm). If clearance is not within specification, check for improper installation.
  10. Install thrust bearing and race on forward clutch assembly with flat side toward clutch assembly. Install new "O" ring on 2nd coast brake piston. Install washer, spring and piston to piston rod. Install "E" ring.
  11. Install 2 oil seals to piston cover. Install spring, 2nd coast brake piston assembly and piston cover to case. Install snap ring.
  12. Place reference mark on 2nd coast brake piston rod. Apply compressed air at opening in transmission case. See Figure . Measure piston stroke between reference mark and case. Piston stroke should be .059-.118" (1.49-2.99 mm). If not within specification, check for improper installation.
  13. Install race on overdrive support. Align bolt and oil holes of overdrive support toward valve body side and bolt hole of case and install.
  14. Ensure support is properly aligned. Install support snap ring with chamfered edge toward front of transmission. End of snap ring must be positioned to valve body side of case within .94" (23.9 mm) from center line of valve body as viewed from front of transmission.
  15. Install support-to-case bolts and torque to 19 ft. lbs. (26 N.m). Measure output shaft end play. End play should be .0106-.0339" (.269-.861 mm). If end play is not within specification, check for improper installation. Ensure output shaft rotates smoothly.
    NOTE: Clutch discs should be soaked in ATF for at least 30 minutes prior to installation.
  16. Install overdrive brake assembly starting with .157" (3.98 mm) thick flange. Flange must be installed with rounded edge facing disc. See Fig 4 .
  17. Starting with disc and alternating with a plate, install correct amount of discs and plates. Install flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are not located at cutout areas of case.
  18. Measure overdrive brake piston stroke by applying compressed air at opening of transmission case. See Fig 4 . Piston stroke should be .0520-.0638" (1.320-1.620 mm). If piston stroke is less than specification, check for improper installation.
  19. Once correct clearance is obtained, remove snap ring and brake components. Install thrust bearing and races on overdrive support. Ensure race tabs align with holes of support. Install overdrive planetary ring gear. Install thrust bearing and race in ring gear. Install race on rear of overdrive planetary gear, aligning race tabs with holes of gear.
  20. Install overdrive planetary gear and OD direct clutch. Install thrust bearing and race on OD direct clutch. Install OD brake assembly starting with .157" (3.98 mm) thick flange. Flange must be installed with rounded edge facing disc.
  21. Starting with disc and alternating with a plate, install correct amount of discs and plates. Install flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are not located at cutout areas of case.
  22. Install race on rear of oil pump with raised side toward oil pump. Install new "O" ring on outer diameter of oil pump. Ensure seal rings are installed on rear of oil pump. Place oil pump on input shaft. Align holes of oil pump and case. Hold input shaft and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum.
    NOTE: DO NOT  apply excessive pressure on oil pump during installation or seal rings will stick to direct clutch drum.
  23. Install oil pump bolts and torque to 16 ft. lbs. (22 N.m). Ensure input shaft rotates smoothly. Install new "O" ring on throttle cable. Install throttle cable. Install new brake drum gasket to case.
  24. Apply air pressure to specified oil passage to check operating components. See Fig 5 . Component application should be heard while applying air.
    NOTE: When air checking rear clutch, overdrive accumulator piston hole must be plugged.
  25. Coat accumulator piston "O" ring with ATF and install on piston. Determine accumulator piston, spring and pin reference location. See Fig 6 . Accumulator piston and pin must be proper diameter and height. See ACCUMULATOR PISTON SPECIFICATIONS  . See ACCUMULATOR PIN SPECIFICATIONS  .
  26. Determine proper spring free length and outer diameter for accumulator piston application. See ACCUMULATOR SPRING SPECIFICATIONS  .
  27. Install piston, springs and pins. Install check ball body and spring. Align manual valve groove with lever pin. Connect throttle cable to cam. Ensure accumulator piston springs are installed correctly. Install valve body. Torque valve body bolts to 89 INCH lbs. (10 N.m). See Figure .
  28. Use new "O" ring on solenoids. Insert solenoid wiring to case and install stopper plate. Connect No. 1, No. 2 and No. 3 solenoids. Using plastic hammer, install oil tubes. DO NOT  bend or damage tubes.
  29. Install oil strainer case with gaskets to valve body. Torque oil strainer case bolts to 89 INCH lbs. (10 N.m). Install oil strainer with new gasket on oil strainer case. Torque oil strainer bolts to 61 INCH lbs. (6.9 N.m). Install magnet in oil pan. Ensure magnet does not interfere with oil tubes.
  30. Apply liquid gasket Three Bond (1281) to oil pan sealing area prior to installation. Install oil pan and torque bolts to 65 INCH lbs. (7.4 N.m).
  31. Install snap ring on output shaft. Install key, sensor rotor and snap ring to output shaft. Apply liquid gasket Three Bond (1281) to transfer case. Install 3 apply gaskets to transfer case. Install transfer case to transmission case. Torque bolts to 25 ft. lbs. (34 N.m). See Figure .
  32. Install transfer front support to transfer case. Torque bolts to 25 ft. lbs. (34 N.m). Install bearing on front support. Using hooks, install direct clutch to transfer case. Install snap ring.
  33. Install bearing and race on sun gear. Install sun gear into direct clutch. Install bearing to rear side of sun gear. Install bearing race to output shaft. Install output shaft to transfer case.
  34. Install transfer low speed brake inner flange to case. Starting with a disc and alternating with a plate, install correct amount of discs and plates. Install brake flange. Install cushion plate with rounded end facing forward. Install low speed brake piston return spring.
  35. Install bearing to center support. Align oil and bolt holes of center support and transfer case. Install center support. Compress center support and install snap ring.
  36. Install snap ring to output shaft. Install front direct clutch and snap ring. Install front output shaft into front direct clutch. Apply liquid gasket Loctite (518) to transfer chain case. Install transfer chain case to transfer case. Install bolts and torque to 25 ft. lbs. (34 N.m).
  37. Install drive chain with sprocket and driven shaft to transfer case. Install snap ring to output shaft. Apply liquid gasket Loctite (518) to chain cover. Install chain cover to transfer case. Install bolts and torque to 25 ft. lbs. (34 N.m).
  38. Install speedometer drive gear. Apply liquid gasket Loctite (518) to extension housing. Install extension housing to transfer rear cover. Torque bolts to 25 ft. lbs. (34 N.m). Install front and rear companion flanges, washers and new companion flange nuts. Using Holding Wrench (J-8614-01), torque nut to 91 ft. lbs. (123 N.m). Stake nuts to shaft.
  39. Check for sound of operation for direct clutch, low speed brake and front drive clutch while applying low pressure compressed air into oil holes. If no noise occurs, check for improper installation of components. Install parking lock pawl bracket. Torque bolts to 61 INCH lbs. (6.9 N.m). Install No. 4 solenoid wire into transfer case. Install wire clamp bolt. Torque bolt to 12 ft. lbs. (16 N.m).
  40. Install transfer valve body. Torque bolts to 89 INCH lbs. (10 N.m). See Fig 5 . Install magnets in transfer oil pan. Apply liquid gasket Three Bond (1281) to oil pan. Apply seal lock adhesive Three Bond (1324) to 4 bolts. See Fig 8 . Install transfer oil pan and torque bolts to 65 INCH lbs. (7.4 N.m).
  41. Install speed sensor and clamp bolt. Connect speed sensor wiring connector. Torque bolt to 65 INCH lbs. (7.4 N.m). Install transfer position switch and wiring clamp. Torque mounting nut to 65 INCH lbs. (7.4 N.m). Install shaft handle and torque to 12 ft. lbs. (16 N.m).
  42. Adjust transfer position switch by loosening transfer position switch bolt and setting transfer shift lever to H4 position. Align basic line and switch groove. Hold in position and torque bolt to 115 INCH lbs. (13 N.m).
  43. Install transmission housing. Torque 10 mm bolts to 25 ft. lbs. (34 N.m) and 12 mm bolts to 42 ft. lbs. (57 N.m). Install thermo sensor to transmission case. Torque bolts 11 ft. lbs. (15 N.m).
  44. Install front and rear unions and torque to 21 ft. lbs. (29 N.m). Using control shaft lever, pull manual lever shaft back and return 2 notches. Manual valve shaft is now in neutral. Insert neutral start onto manual valve shaft and temporarily tighten adjusting bolt. Install lock washer. Install nut and torque to 61 INCH lbs. (6.9 N.m)
  45. Align neutral basic line and switch groove. Torque neutral start switch adjusting bolt to 115 INCH lbs. (13 N.m). Bend at least 2 lock washer tabs. Install control shaft lever. Torque to 12 ft. lbs. (16 N.m).
  46. Install torque converter. Using calipers and straightedge, measure distance from front of converter to front surface of transmission housing. If torque converter is fully installed, distance should be 1.220" (31.00 mm).
ACCUMULATOR PISTON SPECIFICATIONS

Application Diameter In. (mm) Height In. (mm)
2nd Brake 1.453 (36.90) 2.697 (68.50)
Direct Clutch 1.453 (36.90) 2.465 (62.60)
OD Brake 1.256 (31.90) 2.047 (52.00)
OD Direct Clutch 1.177 (29.90) 1.929 (49.00)
ACCUMULATOR PIN SPECIFICATIONS

Application Diameter In. (mm) Height In. (mm)
2nd Brake .472 (12.00) 1.378 (35.00)
Direct Clutch .539 (13.70) 1.307 (33.20)
ACCUMULATOR SPRING SPECIFICATIONS

Application Diameter In. (mm) Height In. (mm)
2nd Brake
Inner .776 (19.70) 2.106 (53.50)
Outer .764 (19.40) 1.811 (46.00)
Direct Clutch
Inner .799 (20.30) 1.894 (48.10)
Outer .827 (21.00) 1.732 (44.00)
OD Brake .650 (16.50) 2.598 (66.00)
OD Direct Clutch .701 (17.80) 2.638 (67.00)
Fig 1: Aligning 1st & Reverse Brake Pack Splines
G96A16238Courtesy of ISUZU MOTOR CO.
Fig 2: Measuring Brake Clearance
G96B16239Courtesy of ISUZU MOTOR CO.
Fig 3: Measuring Input Drum & Rear Clutch Drum Clearance
G96E16240Courtesy of ISUZU MOTOR CO.
Fig 4: Installing & Checking Overdrive Brake
G96F16241Courtesy of ISUZU MOTOR CO.
Fig 5: Testing Component Locations With Air
G96G16242Courtesy of ISUZU MOTOR CO.
Fig 6: Determining Accumulator Piston & Pin Location
G96H16243Courtesy of ISUZU MOTOR CO.
Fig 7: Identifying Transfer Valve Body Bolts
G96I16244Courtesy of ISUZU MOTOR CO.
Fig 8: Identifying Transfer Oil Pan Bolt Sealing
G96J16245Courtesy of ISUZU MOTOR CO.
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