GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2002 🢒 Isuzu T-Series (Truck Line C) 🢒 General Information 🢒 General Information 🢒 Transmission Replacement

Removal Procedure
  1. Block the wheels of the vehicle.

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Disconnect the negative battery cable.

    3. Object Number: 199880 Size: SH

    Important: Before you disconnect any air operated components or air lines, bleed all air pressure from the system.

    Check what type of front engine mount is used. If a single cushion center mount is used, support the engine with an overhead hoist during transmission or clutch replacement.

    Important: When removing or installing the transmission, use a transmission dolly jack in order to support the weight of the transmission. Fasten a safety chain over the top of the transmission and to both sides of the dolly.

  3. Shift the transmission into neutral.
  4. Remove the shift cables from the transmission. Refer to Shift Cable Replacement .

    5. Object Number: 650466 Size: SH
  5. Remove the electric connectors, as necessary.
  6. Remove the clutch actuator from the transmission. Refer to Clutch Actuator Cylinder Replacement .
  7. Remove the oil from the transmission.
  8. Remove the muffler, if required. Refer to Muffler Replacement .
  9. Remove the parking brake cable. Refer to Park Brake Cable Replacement in Park Brake.
  10. Remove the propeller shaft. Refer to the proper procedure:
    11. •  One-Piece Propeller Shaft Replacement
    •  Two-Piece Propeller Shaft Replacement
    •  Three-Piece Propeller Shaft Replacement
  11. Position a transmission dolly jack under the vehicle. Adjust the dolly jack in order to carry the weight of the transmission.
  12. Remove the rear support beam, if used.

    13. Notice: When removing the transmission, do not allow the weight of the transmission to hang on the clutch disc hub. The clutch disc will become distorted and seriously affect the operation of the clutch.

  13. In order to remove the transmission from the engine, SAE number 2 flywheel housing, perform the following procedure:
    14. 13.1. If the engine rear mounting is attached to the transmission, support the engine weight with a hoist or jack.
    13.2. Remove the engine rear mounts.
    13.3. Adjust the transmission dolly in order to support the transmission's weight.
    13.4. Remove all bolts attaching the clutch housing to the engine.
    13.5. Move the transmission straight back from the engine. Keep the mainshaft in alignment with the clutch disc hub.
    13.6. When the transmission is free from the engine, lower and remove the transmission from beneath the vehicle.

Installation Procedure
  1. Shift the transmission into high gear.

    2. Object Number: 199880 Size: SH
  2. Mount the transmission on a suitable dolly and move the transmission into position under the vehicle.
  3. Rotate the output flange or yoke to align the main drive gear shaft with the clutch disc hub.

    4. Notice: When removing the transmission, do not allow the weight of the transmission to hang on the clutch disc hub. The clutch disc will become distorted and seriously affect the operation of the clutch.

    Important: 

       • Avoid springing the clutch when you install the transmission.
       • Do not let the transmission drop or hang unsupported in the splined hub of the clutch disc.

  4. Move the transmission forward, guiding the main drive gear shaft into the clutch disc splines.

    5. Install the transmission into the vehicle.

  5. In order to install apron type flywheel housing, perform the following steps:
    6. 5.1. Install the upper bolts and washers that attach the transmission to the flywheel housing.
    5.2. Install the lower bolts and washers that attach the transmission to the flywheel housing.

    Tighten
    Tighten all the attaching bolts to 142 N·m (105 lb ft).

    5.3. Install the engine rear mounts.
    5.4. Remove the dolly.
  6. Install the propeller shaft. Refer to the proper procedure:
    7. •  One-Piece Propeller Shaft Replacement
    •  Two-Piece Propeller Shaft Replacement
    •  Three-Piece Propeller Shaft Replacement
  7. Install the parking brake cable. Refer to Park Brake Cable Replacement in Brakes.
  8. Install the shift cables to the transmission. Refer to Shift Cable Replacement .
  9. Install the muffler, as necessary. Refer to Muffler Replacement
  10. Install the electrical connectors, as necessary.
  11. Install the clutch actuator. Refer to Clutch Actuator Cylinder Replacement .
  12. Fill the transmission with transmission oil. Refer to Shift Cable Replacement .