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Home >> Isuzu >> 2004 >> Axiom 2WD V6-3.5L >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul (Major Components - 3) >> Reassembly
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Reassembly

Major Components (3)
Reassembly





1. Coat the assembled bearing and race with petroleum jelly and install it onto the transmission case.





Assembled bearing and race (Reference)

2. Install the rear planetary gear, second brake drum and output shaft.





^ Align the teeth of the second brake drum, flanges, discs and plates as shown in the figure.





^ Align the splines of the transmission case and the assembled rear planetary gear, second brake drum and output shaft, indicated by A in the figure.





3. Using snap ring pliers, install the snap ring.





4. Check pack clearance of first and reverse brake.
Using a thickness gauge, measure the clearance between the plate and second brake drum as shown in the figure.
Clearance: 0.60 - 1.12 mm (0.0236 - 0.0440 inch)
If the values are nonstandard, check for an improper installation.





5. Install second brake piston sleeve.





6. Install one-way clutch in the transmission case.





7. Install discs and plates (B-2).
Instal the 2.5 mm (0.098 inch) thick plate with the rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)





8. Install the snap ring.





9. While turning the sun gear input drum clockwise, install it into the one-way clutch

NOTE: Confirm the thrust washer is installed correctly.





10. Install the front planetary gear and bearing to the sun gear.

NOTE: Confirm the bearing and race is installed correctly.





Bearing and race diameter (Reference)





With wooden blocks under the output shaft, stand the transmission on the output shaft.





11. Using snap ring pliers, install the snap ring.





12. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.





Bearing race diameter (Reference)





13. Insert the second coast brake band to the transmission case.
14. Install the E-ring and pin.





^ Install the pin through the brake band.





^ Install the E-ring to the pin.





15. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.





Bearing and race diameter (Reference)





16. Coat the race with petroleum jelly and install it onto the front planetary ring gear.





Race diameter (Reference)





Align the flukes of the discs in the forward clutch.





17. Align the spline of the front planetary gear with the flukes of the discs and install the front planetary gear to the forward clutch.





18. Coat the bearing and race with petroleum jelly and install them onto the ring gear.





Bearing and race diameter (Reference)





19. Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission case.





^ Using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum as shown in the figure.
Height: 2.5 - 4.5 mm (0.098 - 0.177 inch)
If the values are nonstandard, check for an improper installation.





Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.





Assembled bearing and race diameter (Reference)

Part 1:




Part 2:





20. Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the second coast brake piston.
Install the washer, spring and piston to the piston rod. Install the E-ring.





21. Coat two new oil seals with ATF and install them to the piston cover.
Install the spring, second coast brake piston assembly and piston cover to the transmission case.
Using snap ring pliers, install the snap ring.





22. Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod as shown in the figure.
Using wire gauge, measure the stroke by applying the compressed air (390 - 780 kPa or 57 - 114 psi) as shown in the figure.
Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)





If the values are nonstandard, check for an improper installation.





23. Coat the race with petroleum jelly and install it onto the overdrive support assembly.





Race diameter (Reference)





24. Aim the bolt and oil holes of the overdrive support toward the valve hole side, and align them with the bolt hole of the transmission case and insert the overdrive support.





25. Using snap ring pliers, install the snap ring as shown in the figure.





^ Install and tighten the two bolts.
Torque: 25 Nm (19 ft. lbs.)





26. Check end of output shaft.
Using a dial indicator, measure the end play of the output shaft by hand.
End play: 0.27 - 0.86 mm (0.0106 - 0.0339 inch)





27. Install the (flat ring) 4.0 mm (0.157 inch) thick flange with the rounded edge side of the flange facing the disc.
Alternately install four discs and four plates. (Disc first)





28. Install the (stepped ring) flange with the flat side of the flange facing the disc. Install the snap ring.





Snap ring (Reference)





29. Check piston stroke of overdrive brake.
Place a dial indicator onto the overdrive brake piston as shown in the figure.
Measure the stroke by applying and releasing the compressed air (390 - 780 kPa or 57 - 114 psi) as shown in the figure.
Piston stroke: 1.40 - 1.70 mm (0.0551 - 0.0669 inch)





If the values are nonstandard, check for an improper installation.





Available flange size





Remove the snap ring.





Remove one flange, four plates and four discs.





30. Coat the bearing and races with petroleum jelly and install them onto the overdrive support.





Bearing and races diameter (Reference)





31. Install the overdrive planetary ring gear.





32. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.





Bearing and race diameter (Reference)

Install the (flat ring) 4.0 mm (0.157 inch) thick flange with the rounded edge side of the flange facing the disc.
Alternately install four discs and three plates. (Disc first)
Install the (stepped ring) flange with the flat side of the flange facing the disc.
Install the snap ring.





33. Coat the race with petroleum jelly and install it onto the planetary gear.





Race diameter (Reference)





34. Install the overdrive planetary gear and direct clutch.





35. Coat the assembled bearing and race with petroleum jelly and install it onto the direct clutch.





Bearing and race diameter (Reference)





36. Coat the race with petroleum jelly and install it onto the oil pump.





37. Coat the O-ring with ATF and install it around the pump body.
Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.

Install the seven bolts.
Torque: 22 Nm (16 ft. lbs.)





38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.

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