A/T - Flushing Procedures

BULLETIN NUMBER:
IB02-05-S004

ISSUE DATE:
NOVEMBER 2002

GROUP:
TRANSMISSION

AUTOMATIC TRANSMISSION FLUSHING PROCEDURES

AFFECTED VEHICLES

All current Isuzu vehicles with automatic transmissions that requires a transmission replacement.

SERVICE INFORMATION

As part of the normal repair procedure for replacement of the automatic transmission, flushing the transmission cooler and associated lines/pipes must be performed.

To avoid a second failure, the flushing procedure is required to insure that all debris and contaminants including metal, band material and burnt transmission fluid are removed prior to installation of the new transmission. The flush procedure is part of the replacement procedure and if not properly performed will often result in immediate failure of the replacement transmission.

The flushing procedure should be completed using a Transmission Cooling System Flusher (J-35944 or equivalent) to insure that all of the pipes and cooler are reverse flushed.

Follow the flushing procedure provided by the manufacturer of your flushing equipment. These procedures should be used as a standard practice after removing a defective transmission:

1. After removing the defective transmission, identify the two transmission cooler lines. Identify which line is the outlet and which line is the return line to the transmission cooler.

2. Attach the flush machine so that the flow of flush solution is the reverse of the transmission fluid flow. Be sure to use only approved Oil Cooler Flushing Fluid.

3. After the flushing procedure is complete and the replacement transmission has been installed a flow test must be completed.

FLOW TEST PROCEDURES

Important:
The Flow Test must he performed after the flush to ensure that all flushing solution and water is removed from the system.





1. Connect a hose from the transmission cooler return outlet side to an empty container capable of measuring fluid level. (Figure 1)

2. Confirm the transmission is filled with automatic transmission fluid. Refer to Fluid Capacity Specifications in the workshop manual for the correct automatic transmission fluid capacity.

3. Start the engine with the transmission in Park range and run for 30 seconds after fluid begins to flow from the discharge hose. A minimum of 1.9L (2 quarts) must be discharged during this 30 second run time.

4. If the fluid flow meets or exceeds 1.9L (2quarts) in 30 seconds the flow test is complete.

5. Reconnect all hoses to the transmission.

6. Check and adjust automatic transmission fluid level (refer to the workshop manual for proper procedure and capacity).