clutch thickness ISUZU TF SERIES 2004 User Guide

MANUAL TRANSMISSION 7B1-99

1st-2nd Synchronizer (3-CONE)

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.

Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance


Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.

226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.158 in)
1st-2nd3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)

Clutch Hub and Insert Clearance


Use a thickness gauge to measure the clearance
between the clutch hub and the insert.

226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.

Clutch Hub and Insert Clearance
Standard Limit
1st-2nd
3rd-4th 0.01 – 0.21 mm
(0.004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)

MANUAL TRANSMISSION 7B1-103





266RS049
7. Install the synchronizer assembly (20) to the
mainshaft (26).
The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.

226RS048
8. Install clutch hub snap ring(19) by performing the
following steps:


Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring.




226RS050

There are three snap ring sizes available.

The snap rings are color coded to indicate their
thickness as shown in the figure.

226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)

Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue

Use a pair of snap ring pliers to install the snap
ring (19) to the mainshaft (26).
The snap ring must be fully inserted into the
mainshaft snap ring groove.

MANUAL TRANSMISSION 7B1-105

12. Apply engine oil to the needle bearing (10) and the
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.

226RS056
13. Install 3rd block ring (8).
14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the 3rd gear side.

226RW221

226RS049
15. Select and install mainshaft snap ring(6) in the
following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.

226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.

7B1-106 MANUAL TRANSMISSION


226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)

Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue


Use a pair of snap ring pliers to install the snap
ring to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
16. Install top block ring (5).
Apply grease to the needle bearing (4) inner and
outer circumferences and install needle bearing (4)
in the top gear shaft (2).
17. Use a bench press to install the top gear shaft ball
bearing (3) to the top gear shaft (2).

226RS059
The snap ring groove of the ball bearing (3) must be
facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gear
shaft snap ring (1) to the top gear shaft (2).

7D-22 TRANSFER CASE

Block Ring and Insert Clearance
1.
Use a vernier caliper to measure the clearance
between the block ring and the insert.
2.
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.

Block ring and insert clearance
Standard : 3.86 – 4.14 mm (0.152 – 0.163 in)
Limit : 4.9 mm (0.193 in)

226RS037

2WD-4WD Synchronizer (3-Cone)
1.
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2.
If the measured value exceeds the specified limit,
the 2WD-4WD synchronizer assembly must be
replaced.
Block ring and dog teeth clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)





226R300019

Clutch Hub and Insert Clearance
1.
Clutch Hub and Insert Clearance
2.
Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
3.
If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01-0.19 mm (0.0004-0.0075 in)
Limit : 0.3 mm (0.012 in)


226RS038

Detent Springs
1.
Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.

7A4–26 UNIT REPAIR (AW30–40LE)
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 in)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 001 6
5. Install second brake piston sleeve.
24 6RY 0 000 4
6. Install one-way clutch in the transmission case.
24 7RY 0 0011
7. Install discs and plates (B–2).
Instal the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)
24 6RY 0 0005

UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 002 7
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
25 2RY 0 002 8
3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
25 2RY 0 0029
4. Check OD direct clutch drum bushings.
Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in)
If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
25 2L10 0009

UNIT REPAIR (AW30–40LE) 7A4–51
13. Install two plates and two discs then install the
flange, with the flat side facing downward.
2 52L10 001 3
14. Install snap ring.
2 52L10 001 4
15. Check piston stroke of OD direct clutch (C–0)
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
25 2L10 0005Using a dial indicator, measure the OD direct clutch
piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
25 2L10 0016
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
24 8RY 0 003 0
8. Remove two O-rings from piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)
24 7RY 0 003 4
2. Check discs.
Using micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 0027
3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031

UNIT REPAIR (AW30–40LE) 7A4–63
Flange sizes
RUW 37A SH00 490 1
9. Coat the clutch drum thrust washer (plastic) with
petroleum jelly and install it onto the direct clutch.
NOTE: Make sure that the lugs fit into the cutout
portions on the direct clutch.
24 8RY 0 003 7
Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward
clutch assembly.
Check that the distance from the direct clutch end to
the forward clutch end is 71.2 mm (2.803 in).
24 8RY 0 0038
Flange thickness Flange thickness
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.4 mm (0.134 in)—
3.5 mm (0.138 in) 4.0 mm (0.157 in)
3.6 mm (0.142 in)—
3.7 mm (0.146 in) 4.2 mm (0.165 in)