Service Procedure

DIAGNOSIS:

If any other DTC's are set, resolve the other codes before performing this bulletin on DTC P1870.

If DTC P1870 is the only code do the following:

^ Remove both the main and adapter case transmission oil pans and check for metal and fiber debris.

^ If more than 1 tablespoon of metallic and fiber debris is found, THIS REPAIR WILL NOT BE SUCCESSFUL. Call the Isuzu Technical Assistance Line for direction and a possible Concurrence Code for warrantable cases. Note: Not available for Aftermarket.

CORRECTIVE ACTION:

Replace the Separator Plate Gaskets and use the increased torque specification for the main case bolts.

1. Reinstall the oil pans with the original gaskets.

2. Remove the transmission from the vehicle. (4WD recommendation: remove the transfer case before removing the transmission.) See Rodeo (UE) Service Manual section 7A.

3. Clean the outside of the transmission.

4. Attach the holding fixture to the transmission, Special Tool P/N J-8763-02 (Trans Holding Fixture) & J-3289-20 (Base). Secure the transmission with the input shaft pointing up.

NOTE:
To avoid damaging transmission do not over tighten the holding fixture.

5. Place an oil catch pan under the transmission.

6. Slide the torque converter off the transmission. Avoid damaging the pilot by carefully setting the converter on the bench with the opening up.

7. Remove the oil pans.

8. Remove the adapter case harness.





9. Remove the turbine shaft 0-ring and discard it (Figure 1).





10. Remove the seven case housing bolts at the outer ring, Not the 5 inner bolts (Figure 2).





11. Lift the converter housing and oil pump assembly straight up. Set the assembly on the bench with the pump side up (Figure 3).





NOTE:
Do Not lift the Pump by the Turbine Shaft (Input); it's connected to the Overdrive Carrier that remains in the Transmission Housing.

Continued at Step 14.

14. Replace the case 0-ring and gasket (8-96017-189-0 0-ring & 8-96014-973-0 gasket) (Figure 4).





15. Wet the new gasket and 0-ring with, DEXRON-III (Figure 5).

16. Line-up the case holes with the gasket and install the 0-ring without twisting it.

17. Use petroleum jelly (ONLY) to hold the selective thrust washer in place.





18. Replace the turbine shaft scarf-cut plastic seals (8-96017-484-0 scarf seals 2x) (Figure 6).

19. Apply petroleum jelly in the seal groves to hold the new seals in place.

Note:
Be sure the angled cut ends are properly matched or the new seals will not seal properly.





20. Grab the turbine shaft and lift out the 4th clutch, 4th retainer, & overrun assembly (Figure 7).





21. Remove the remaining steel 4th clutch plate (Figure 8).





22. Remove the overdrive internal gear and thrust bearing (Figure 9).

23. Remove the thrust washer.





24. Lift the adapter case off the main case (Figure 10).





25. Remove the selective washer from the center support housing (Figure 11).





26. Remove two oil passage 0-rings from the main case (Figure 12). Discard them.

27. Install two oil passage 0-rings on the main case (8-96014-270-0 0-Ring, Case Drain Back 2x). Lube them with ATF (Figure 12).





28. Compress the reverse spring seat with Special Tool P/N J-23327 (Reverse Spring Seat Compressor) (Figure 13).





29. Remove and discard the retaining (snap) ring (Figure 14).

30. Remove the compressor tool and spring seat. Discard the spring seat.





31. Remove the reverse piston. Discard the inner & outer 0-rings (Figure 15).

32. Remove the center support bolts.





33. Remove the center support housing from the adapter case (Figure 16).

34. Use a plastic hammer if necessary.








35. Replace the separator plate gaskets (8-96016-514-0 gasket 2x) Figure 17 & 18).

IMPORTANT:
These gaskets will look deformed They are the primary internal leak. If both gaskets are flat, inplace, and not torn, !STOP! replacing them will not fix the transmission. Install a reman trans.





36. Be sure the oil restrictor is in the correct location (Figure 19).

37. Stack the gasket, separator plate, gasket, center support on the adapter case (Figure 10).

38. Use the two 9 inch guide pins and the center support bolts to lineup the gaskets & plate, Special Tool P/N J-38588.

39. Reinstall the center support bolts. Torque to 25 N-m (18 lb-ft).





40. Install the inner & outer reverse piston 0-rings (8-96014-331-0 inner seal & 8-96014-332-0 outer seal). Lube them with ATF or petroleum jelly (Figure 20).

41. Reinstall the reverse piston. A tool is not required to guide the o-rings (Figure 20).





42. Place the springs (24) on the piston. Replaced damaged springs as needed (8-08958-719-0 spring) (Figure 21).

43. Install the new spring seat (8-05258-021-0) and compress the springs with the compressor, Special Tool P/N J-23327 (Reverse Spring Seat Compressor) (Figure 13).

44. Install the new retaining (snap) ring (8-05258-093-0) and remove the compressor.

45. Reinstall the selective washer with grease to hold it.

46. Install a new case 0-ring (8-96017-189-0). Lube it with ATF.





47. Install the two 9 inch guide pins, Special Tool P/N J-38588 (Figure 22).

48. Install the adapter case.





49. Reinstall the thrust washer, tangs toward the adapter case in their slots (Figure 23).

50. Lube the washer with ATF.

51. Reinstall the overdrive internal gear and thrust bearing. Lube with ATF (Figure 9).

NOTE:
Thrust bearing outer case [aces the internal gear.

52. Remove the 4th clutch & 4th retainer from the overrun assembly (Figure 8).





53. Reinstall the turbine shaft and overrun assembly (Figure 24).

54. Reinstall the 4th clutch, steel, lined, steel, steel, lined, steel (Figure 8).

55. The steel plates go in with the short tang towards the valve body.

56. Reinstall the 4th retainer, cut-out notch facing up & toward the valve body (Figure 8).

57. Place the new gasket on the adapter case (Figure 4).

58. Lower the converter housing and oil pump assembly onto the adapter case (Figure 3).

59. Press the converter housing and oil pump assembly and case together by hand.





60. Install two of the seven housing bolts, hand tight (Figure 25).

61. Remove the two 9 inch guide pins (Figure 22).

62. Install the remaining housing bolts (seven total) and torque them to 54 N-m (40 lb-ft) in a cross pattern. THIS IS AN INCREASED TORQUE SPEC (Figure 25).

63. Install a new turbine shaft 0-ring (8-96013-953-0). Lube it with ATF.

64. Reinstall the adapter case harness. Torque the valve body bolt to 20 N-m (15 lb ft).

65. Install new oil pan gaskets without any sealer (8-96014-234-0 gasket, main & 8-96014-235-0 gasket, adapter).

66. Remove the transmission from the holding fixture and set it, pan down, on the bench.

67. Lubricate the oil pump seal and the converter sealing surface with DEXRON-III.

68. Slide the converter onto the transmission. Turn and push to align the turbine shaft, the stator shaft, and the oil pump. The converter must be completely inside the bellhousing.

69. Reinstall the transmission.

NOTE 1:
The bellhousing bolt located two holes above the starter motor must be no longer than 40 mm. If a longer bolt is used, it will break into the engine coolant jacket.

NOTE 2:
Before installing the converter to the drive plate bolts, push the converter into the transmission and check the gap between the converter and drive plate. A 10 mm gap (or more) must exist otherwise the oil pump will be damaged when the engine is started. If the gap is too small, remove the transmission, then turn and push the converter to

70. Set the transmission fluid level. See Rodeo (UE) Service Manual section 7A.

71. Test-drive the vehicle.