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Home >> Isuzu >> 2004 >> Rodeo 3.2 W, 4WD, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission (Aw3040LS) >> Components (1) >> Reassembly

Components (1): Reassembly

  1. Install a new gasket and the extension housing (4x2) to the transmission case.

    Torque:  36 N.m (27 lb ft)

  2. Install the speedometer driven gear, plate, and speedometer sensor (4x2).

    Torque: 

    Plate bolt - 15 N.m (11 lb ft)

    Speedometer sensor - 25 N.m (18 lb ft)

  3. Install the adapter housing (4x4).
    • Remove any gasket material on the contacting surfaces of the adapter housing and transmission case.
      Fig 1: Installing Adapter Housing
      G02794992Courtesy of ISUZU MOTOR CO.
    • Apply liquid gasket (TB1281-B or its equivalent) (1) and install the apply gaskets (2) to the adapter housing as shown in the figure.
    • Install the adapter housing to the transmission case.

      Torque:  34 N.m (25 lb ft)

  4. Install the neutral start switch.
    • Using the transmission select lever, fully turn the manual valve lever shaft back and return two notches.

      It is now in neutral.

    • Insert the neutral start switch onto the manual valve lever shaft and temporarily tighten the adjusting bolt.
    • Install the lock washer and nut.

      Torque:  7 N.m (61 lb in)

    • Align the neutral standard line and the switch groove and tighten the adjusting bolt.

      Torque:  13 N.m (113 lb in)

    • Bend the tabs of the lock washer.
    NOTE: Bend at least two of the lock washer tabs.
    Fig 2: Installing Neutral Start Switch
    G02794993Courtesy of ISUZU MOTOR CO.
  5. Install the oil temperature sensor to the transmission case.

    Torque:  15 N.m (11 lb ft)

    Fig 3: Installing Oil Temperature Sensor To Transmission Case
    G02794994Courtesy of ISUZU MOTOR CO.
  6. Install the elbow.
    • Coat new O-rings with ATF, install them to the two elbows.
    • Install the two elbows as shown in the figure.

      Torque:  29 N.m (3.0 kg.m/22 lb ft)

      Fig 4: Installing Elbows
      G02794995Courtesy of ISUZU MOTOR CO.
  7. Install the select lever.
  8. Install the output revolution sensor (4x2).
  9. Install the output revolution sensor (4x4).
  10. Install the input revolution sensor.
  11. Install the breather hose.
  12. Install the torque converter.

    Using calipers and a straightedge, measure the distance from the installed surface of the transmission housing to top of the torque converter nut.

    Correct distance:  13.5 mm (0.53 in)

    Fig 5: Measuring Distance From Installed Surface Of Transmission Housing To Top Of Torque Converter Nut
    G02794996Courtesy of ISUZU MOTOR CO.
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