transmission oil ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20

ON-VEHICLE SERVICE (JR405E) 7A3-3
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20
C (68
F) before the
cold level check is made.
1. Park the vehicle on a level surface.
2. Apply the parking brake firmly.
3. Start the engine and allow it to warm up.
The engine coolant temperature gauge needle
should be midway between the “C” mark and “H”
mark.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each range just long enough for the
transmission to engage.
5. Return the select lever either “P” or “N”.
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.

9. Remove the dipstick.
The ATF level should be inside the “C”range on the
dipstick.
If the ATF level is below the “C” range, ATF must be
added.
242R300002


ATF CHANGE
1. Start the engine and allow it to idle until the ATF
reaches a temperature of 40-50
C
2. Park the vehicle on level ground and block the
wheels.
3. Stop the engine.
4. Raise vehicle and support with suitable safety
stands.
5. Remove the drain plug from the oil pan and drain the
ATF (approximately 6 liters).
6. Remove the oil pan.
7. Inspect the oil pan (details written below).
8. Install the oil pan.
Note:
Use new gasket. Clean the oil pan and magnet.
Oil pan bolt torque : 8 Nm (69 lbin)
9. Replace the gasket and install the drain plug.
Drain plug torque : 35 Nm (26 lbft)
Note:
Do not reuse old washer (gasket).
Clean the drain plug (especially the threaded section).
10. Pour about 5 liters of new ATF. Then, add more ATF
carefully as necessary using the dipstick.
Refer to “ATF LEVEL” previously in this section.
Note:
Keep the engine idle (do not stop it) during the oil level
adjustment.
11. Remove the safety stands and wheel blocks. Inspect
1. Check the drain plug tip for adhesion of foreign
substances.
2. Check the drained ATF for color, smell and inclusion
of foreign substances.
3. Check the oil pan bottom and magnet for adhesion o
f
foreign substances.
If a problem is discovered during those checks, the
Automatic transmission must be overhauled.
Note:
The torque converter and the oil strainer need replaced
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.
In addition, flush the ATF cooler circuit

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.

Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil
Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
6. Fill the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. When the abnormal amount of debris are found.
2. When the abnormal wear or chips on gears and
shafts are found while overhauling.
3. When the abnormal clutch facing wear and oil
contamination are found.

Procedures
1. Block the wheels.
2. Disconnect negative battery cable.
3. Raise vehicle and support with suitable safety
stands.
4. Disconnect fluid cooler lines at transmission case
and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using
solvent and compressed air.
Note:
DO NOT exceed 197 kPa (29 psi) air pressure or
damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic
Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (33 lb·ft)
8. Replenish ATF
9. Start engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all
debris from the fluid cooler circuit.
Move the select lever through the various ranges and
return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF
must be added.
10. Connect negative battery cable.
11. Remove safety stands.
12. Remove wheel blocks.

UNIT REPAIR (JR405E) 7A4-1
SECTION 7A4
UNIT REPAIR (JR405E)
TABLE OF CONTENTS
PAGE
Automatic Transmission Disassembly ..................................................................... 7A4 - 2
Control Valve Assembly ............................................................................................ 7A4 - 11
Control Valve Upper Body ........................................................................................ 7A4 - 18
Control Valve Lower Body ........................................................................................ 7A4 - 23
Oil Pump Assembly ................................................................................................... 7A4 - 28
Clutch Pack (Reverse and High Clutch Assembly) ................................................. 7A4 - 33
Carrier and Low Clutch Assembly ........................................................................... 7A4 - 41
Transmission Case .................................................................................................... 7A4 - 54
Bearing and Bearing Race Installation Position ..................................................... 7A4 - 66
Automatic Transmission Reassembly ..................................................................... 7A4 - 69
Service Standard ....................................................................................................... 7A4 - 83
Special Service Tool .................................................................................................. 7A4 - 85

7A4-2 UNIT REPAIR (JR405E)

AUTOMATIC TRANSMISSION
DISASSEMBLY
Cleaning the automatic transmission
1. Use compressed steam and /or cleaning oil to thoroughly
clean the outside of the transmission before disassembly.
CAUTION:
Steam under high pressure may cause dirt particles
adhering to the transmission to fly through the air at great
speed. These particles can cause serious eye injury. Wear
protective goggles when steam-cleaning the outside of
the transmission.
2. During disassembly, clean the removed parts with cleaning
oil. Dry the parts with compressed air.
Use Compressed air to clean the transmission oil holes
and oil passages.

Automatic transmission disassembly cautions

Perform the disassembly procedure in a dust-free
environment to prevent the entry of foreign material into
the transmission.

Inspect each transmission part as you remove it.

Carefully check the oil pan and the magnet for foreign
material. This is a good way to estimate transmission
condition.

Use your bare hands or vinyl gloves to disassemble the
transmission. Do not use ordinary work gloves (loose
threads from the gloves may fall into the transmission and
cause problems).

Use a plastic hammer to loosen the transmission case
and other aluminum parts during disassembly. Strike
around the parts lightly with the hammer. Do not pry
aluminum parts away from each other with a screwdriver
or similar object.

Arrange the disassembled parts neatly in the order they
were removed. Cover the parts with a plastic sheet or
similar object to protect them from dust.

UNIT REPAIR (JR405E) 7A4-3
Disassembly steps
1. Torque converter

Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.

Draining the ATF from the torque converter.


01ASSY101

2. Turbine sensor and speed sensor

Remove the turbine sensor from the transmission case.



02ASSY103



Remove the speed sensor from the transmission case.



03ASSY106

3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.


240L300002

4. Oil pan

Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0

Remove the drain plug from the oil pan and drain the
ATF from the oil pan.

Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.

Rotate the automatic transmission so that the oil pan is
facing up.

Remove the 19 bolts and the oil pan.

7A4-6 UNIT REPAIR (JR405E)

10ASSY116

6. Converter housing

Position the automatic transmission so that the
converter housing is facing up.

Remove the 8 bolts and the converter housing.



11ASSY068

7. O-ring
Remove the O-ring from the input shaft.


12ASSY067

8. Oil pump assembly and bearing race

Remove the 8 bolts.

Use a slide hammer to remove the oil pump assembly
from the transmission case.
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.

Remove the bearing race from the oil pump assembly.

Inspect the bearing race surfaces for damage.


14ASSY057

9. Input shaft
Pull the input shaft free.


15ASSY049

10.Clutch pack (Reverse and high clutch assembly) and
bearing

Pull the clutch pack free.

Remove the bearing from the clutch pack.

7A4-8 UNIT REPAIR (JR405E)

25ASSY019



Remove the 2-4 brake retainer and return spring.



26ASSY026

14.Carrier assembly (Carrier and low clutch assembly),
bearing, bearing race, and 2 – 4 brake assembly

Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.

Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.



27U-SPG02



Remove the 3 brake springs from the transmission case.



28L&R06

15.Low and reverse brake

Remove the snap ring.

Pull the low and reverse brake free.


16.Rear extension (2WD) or Adapter case (4WD)

Rotate the transmission case so that the oil pan opening
is facing up.

Remove the 10 bolts and the rear extension (2WD) o
r
the adapter case (4WD).

7A4-10 UNIT REPAIR (JR405E)

39ASSY006



Remove the bearing and the low one-way clutch inner
race from the transmission case.

Remove the bearing from the low one-way clutch inne
r
race.


40ASSY005

21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.


41L&R02

22.Low and reverse brake piston

Force compressed air (329kPa/4.0kg/cm
2) through the
transmission case oil passages.


42ASSY004



Remove the low and reverse brake piston from the
transmission case.

7A4-54 UNIT REPAIR (JR405E)

TRANSMISSION CASE

02CASE-BK06
Legend
1. Transmission case
2. Spring pin (slender)
3. Spring pin (fat)
4. Manual plate
5. Detent spring


6. Parking rod
7. Manual shaft
8. Oil seal
9. Inhibitor switch