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Home >> Isuzu >> 2001 >> Rodeo LS, 2.2 D >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul & Testing - 4L30-E >> Transmission Reassembly

Transmission Reassembly

NOTE: Lubricate all components with Dexron-III ATF before reassembly. Coat all thrust bearing assemblies with petroleum jelly before installing. For bearing, bushing, oil seal and thrust washer location reference during reassembly, see Fig 6-Fig 8 .
  1. Install NEW shaft seal for selector shaft in transmission case. Install selector shaft. Install spring pin in transmission case. See Figure. DO NOT install spring pin flush with surface on transmission case.
  2. Install parking lock and range selector lever with actuator rod on selector shaft. Install and tighten selector shaft nut to specification. See TORQUE SPECIFICATIONS .
  3. Install brake band in transmission case. Ensure servo pin area aligns with servo hole. Install thrust bearing assembly in rear of transmission case.
  4. Install brake drum, reaction sun gear and needle bearing. See Figure. Install thrust bearing assembly on output shaft on planetary carrier.
  5. Prior to installation, pinions on planetary carrier must be properly aligned (if markings are present). Each pinion may be marked with 2 dots to indicate master tooth space and a single dot to indicate master tooth. Planetary carrier may be marked with double lines which should align with 2 dots on 2 opposite pinions. Single lines on planetary carrier should align with single dot on other 2 pinions. See Fig 1.
  6. Properly align all pinions on planetary carrier. Install 2nd and 3rd clutch assemblies on planetary carrier. If pinions are properly aligned, 2nd and 3rd clutch assembly should fit easily on planetary carrier.
  7. Rotate 3rd clutch and ensure pinions with 2 dots are at teeth No. 1 and 46 on ring gear in 2nd clutch assembly. See Fig 1. Pinions with one dot should be between teeth No. 23 and 24 on ring gear in 2nd clutch assembly. If not as specified, realign as necessary.
    Fig 1: Aligning Pinions On Planetary Carrier
    G95C20604Courtesy of ISUZU MOTOR CO.
  8. Once correct pinion alignment is obtained, install planetary carrier in transmission case. Install washer and bearing on planetary carrier. See Figure.
  9. Install thrust washer on 2nd clutch. Ensure tangs on thrust washer engage with slots on 2nd clutch. Align tangs on clutch plates in 2nd clutch. Install 3rd clutch assembly in 2nd clutch drum.
  10. Install assembled 2nd and 3rd clutch assemblies in transmission case. Ensure planetary carrier is properly aligned. Rotate output shaft and clutch assemblies to ensure proper engagement.
  11. Install pressure plate in transmission case with flat side up. Lug on pressure plate must engage narrow notch in case that faces oil pan mounting surface. See Figure.
  12. Install reverse clutch plates and clutch discs, starting with clutch plate and alternating with clutch disc. Install waved plate with lugs engaged with narrow notch in transmission case.
  13. The 2nd clutch end play must now be checked. Install Selective Thrust Washer Gauge (J-23085-A) on transmission case, against intermediate shaft. Move inner shaft on selective thrust washer gauge downward against thrust surface on 2nd clutch hub. Perform STEP 1. See Fig 2. Tighten thumb screw on selective thrust washer gauge.
  14. Remove selective thrust washer gauge from transmission case. Install spacer ring on inner shaft of selective thrust washer gauge. Measure distance "G" from end of inner shaft to surface on spacer ring. Perform STEP 2. See Fig 2.
  15. Using dimension "G", determine color of selective thrust washer that fits on center support. See SELECTIVE THRUST WASHER SPECIFICATIONS  table. This should provide a final 2nd clutch end play of .014-.031" (.36-.79 mm).
    SELECTIVE THRUST WASHER SPECIFICATIONS

    Dimension "G" - In. (mm) Color
    .060-.064 (1.53-1.63) Yellow
    .068-.072 (1.73-1.82) Red
    .075-.079 (1.91-2.01) Black
    .083-.087 (2.11-2.21) White
    .090-.094 (2.29-2.39) Green
    .098-.102 (2.49-2.59) Blue
    Fig 2: Measuring 2nd Clutch End Play
    G95D20605Courtesy of ISUZU MOTOR CO.
  16. Install NEW seals on 4th clutch piston. Lubricate seals with Dexron-III ATF. Install 4th clutch piston in adapter case. Use care not to damage seal rings.
  17. Install 4th clutch retainer and spring assembly on 4th clutch piston. See Figure. Using spring compressor, compress 4th clutch spring retainer and spring assembly. Install snap ring in adapter case. Remove spring compressor.
  18. Apply petroleum jelly on selective thrust washer. Install selective thrust washer on center support. Install NEW "O" rings on front of transmission case and a NEW seal ring on the adapter case. See Figure.
  19. Install guide pins in front of transmission case for aligning adapter case at 4 and 11 o'clock positions. Install adapter case and center support assembly on transmission case.
  20. Install thrust washer on adapter case. Ensure tangs on thrust washer engage with slots in adapter case. Apply petroleum jelly on thrust bearing and install at center of overdrive internal gear with Black side of thrust bearing facing upward. See Figure.
  21. Install overdrive internal gear with thrust bearing on turbine shaft and overrun clutch assembly. Install turbine shaft and overrun clutch assembly with overdrive internal gear in adapter case.
  22. Install 4th clutch plates and clutch discs in following order: clutch plate, clutch disc, clutch plate, clutch plate, clutch disc and clutch plate. Clutch plates must be installed with short tang facing toward adapter case valve body surface.
  23. Install 4th clutch retainer with notch area toward adapter case valve body surface. Overdrive clutch end play must now be checked.
  24. Install Selective Thrust Washer Gauge (J-23085-A) on adapter case, against turbine shaft. Move inner shaft on selective thrust washer gauge downward against thrust surface on overrun clutch housing. Perform STEP 1. See Fig 3. Tighten thumb screw on selective thrust washer gauge.
  25. Remove selective thrust washer gauge from adapter case. Measure distance "G" from end of inner shaft to surface on selective thrust washer gauge. Perform STEP 2. See Fig 3.
  26. Using dimension "G", determine color of selective thrust washer that fits on rear of oil pump assembly. See SELECTIVE THRUST WASHER SPECIFICATIONS  table. This should provide a final overdrive clutch end play of .004-.027" (.10-.69 mm).
    Fig 3: Measuring Overdrive Clutch End Play
    G95E20606Courtesy of ISUZU MOTOR CO.
  27. Install NEW outer seal ring on torque converter housing and NEW gasket on oil pump assembly. See Figure. Apply petroleum jelly on selective thrust washer and install on rear of oil pump assembly. Ensure selective thrust washer is fully seated on oil pump assembly.
  28. Install torque converter housing with oil pump assembly and gasket on adapter case. Install and tighten torque converter housing-to-adapter case bolts to specification. See TORQUE SPECIFICATIONS . Ensure oil pump gears rotate freely.
  29. Install dial indicator, end play fixture and turbine shaft puller assembly onto turbine shaft. See Fig 4. Pull turbine shaft upward until slight resistance is felt. Zero dial indicator.
  30. Continue to pull turbine shaft upward and note turbine shaft end play. Turbine shaft end play should be .004-.031" (.10-.79 mm). Remove dial indicator, turbine shaft puller and end play fixture.
  31. If turbine shaft end play is not within specification, different thickness selective thrust washer must be installed on rear of oil pump assembly. Repeat steps  24- 26 for selective thrust washer selection procedure.
    Fig 4: Measuring Turbine Shaft End Play
    G95F20607Courtesy of ISUZU MOTOR CO.
  32. Install NEW bearing in extension housing if replacement is necessary. Install NEW oil seal in extension housing. Install NEW seal ring on parking lock gear if seal ring is damaged. See Figure.
  33. Install parking lock gear, speed sensor drive gear and retaining ring on output shaft. See Figure. Using NEW gasket, install extension housing. Ensure parking pawl shaft and actuator rod are aligned with extension housing. Install and tighten extension housing bolts to specification.
  34. Using a NEW "O" ring, install speed sensor. Install and tighten bolt to specification. Position transmission with output shaft facing upward. Install dial indicator on extension housing with stem of dial indicator against output shaft. See Fig 5. Zero dial indicator.
  35. Manually push output shaft upward and note output shaft end play. Output shaft end play should be .014-.031" (.36-.79 mm). If output shaft end play is not within specification, different thickness selective thrust washer must be installed on center support. Repeat steps  13- 15 for selective thrust washer selection procedure.
  36. Install drive shaft flange and NEW "O" ring on output shaft. Install and tighten drive shaft flange nut to specification.
  37. Ensure brake band is correctly positioned. Rotate output shaft if necessary. Install NEW seal ring on servo piston if necessary. Install apply rod in transmission case with rounded end of rod toward the brake band.
  38. Install return spring and servo piston. Use care not to damage seal ring on servo piston. Using spring compressor, compress servo piston and return spring. Install servo piston retaining snap ring. Remove spring compressor.
  39. To adjust brake band, loosen lock nut on servo adjusting screw. See Figure. Using INCH-lb. torque wrench, tighten servo adjusting screw to 40 INCH lbs. (4.5 N.m).
  40. Back off servo adjusting screw 5 turns. Hold sleeve on servo piston. Tighten lock nut to 14 ft. lbs. (19 N.m). Ensure servo adjusting screw does not rotate while tightening lock nut.
  41. Install 2 check balls in transmission case. See Figure. Install case electrical connector and wiring harness. See Figure. Install guide pins for main valve body in transmission case.
  42. Install assembled main valve body and manual valve link assembly. Manual valve link must be extended, as long end fits into manual valve and short end fits into range selector. Remove guide pins. Install and tighten main valve body bolts in a spiral pattern starting in center of valve body to specification. Install electrical connectors at solenoids on main valve body.
  43. Using NEW gasket, install servo cover. Install and tighten bolts to specification. Install manual detent on main valve body. See Figure. Install and tighten bolts to specification.
  44. Install NEW oil filter. Install and tighten bolts to specification. Using NEW gasket, install main case oil pan. Install and tighten bolts to specification.
  45. Install electrical connector in adapter case. Install adapter case check ball. See Figure. Using NEW transfer plate gaskets, install adapter case valve body and transfer plate. Install and tighten bolts to specification. Install electrical connectors at solenoids on adapter case valve body. See Figure.
  46. Using NEW gasket, install adapter case oil pan. Install and tighten bolts to specification. Install and adjust transmission range switch. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING. Install NEW "O" ring on end of turbine shaft. Install torque converter.
Fig 5: Measuring Output Shaft End Play
G98I01211Courtesy of GENERAL MOTORS CORP.
Fig 6: Identifying Transmission Seal Locations
G98A01212Courtesy of GENERAL MOTORS CORP.
Fig 7: Identifying Transmission Bearing & Bushing Locations
G98C01213Courtesy of GENERAL MOTORS CORP.
Fig 8: Identifying Thrust Washer & Retainer Locations & Direction
G98E01214Courtesy of GENERAL MOTORS CORP.
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