reverse ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-55
01L&R-CS05
Legend
1. Seal ring
2. Low one-way clutch inner race
3. Return spring
4. Low and reverse brake piston
5. Seal ring
6. Lip seal


7. Transmission case
8. Snap ring
9. Retaining plate
10. Driven plate
11. Drive plate
12. Dish plate



04CASE-AY52

Disassembly steps
1. Harness assembly
Remove the fixing bolt and the harness assembly.

UNIT REPAIR (JR405E) 7A4-57

11CASE-AY01

5. Oil seal
Using a screwdriver, remove the oil seal from the
transmission case.




Inspection
2 – 4 brake drive plate
Measure the 2-4 brake drive plate facing thickness at 3
points and calculate the average value.
If the average value is less than the specified limit, the 2-4
brake drive plate must be replaced.
2 – 4 brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
Low and reverse brake drive plate
Measure the low and reverse brake drive plate facing
thickness at 3 points and calculate the average value.
If the average value is less than the specified limit, the lo
w
and reverse drive plate must be replaced.
Low and reverse brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
2 – 4 brake return spring

Check the number of effective 2-4 brake return spring
coils.
Effective return spring coils (Standard): 10.2

Measure the 2-4 brake return spring outside diameter,
free length, and linear diameter.
If any of the measured values exceed the specified limit,
the 2-4 brake return spring must be replaced.
2 – 4 brake return spring measurements (Standard):
Outside diameter = 6.9 mm (0.272 in)
Free length = 22.5 mm (0.886 in)
Linear diameter = 1.1 mm (0.043 in)
Low and reverse brake return spring

Check the number of effective low and reverse brake
return spring coils.
Effective return spring coils (standard): 4.8

Measure the low and reverse brake return spring outside
diameter, free length, and linear diameter.
If any of the measured values exceed the specified limit,
the low and reverse return spring must be replaced.
Low and reverse brake return spring measurements
(Standard):
Outside diameter = 11.2 mm (0.441 in)

7A4-60 UNIT REPAIR (JR405E)

26L&R01

6. Low and reverse brake piston

Install new seal rings to the low and reverse piston.







RTW47ASH000701
As shown in a figure, sealing lip is attached.

27ASSY004



Install the low and reverse brake piston to the
transmission case.


28ASSY005

7. Return spring

Install the return spring to the low and reverse brake
piston.


29ASSY006

8. Low one-way clutch inner race

Install the low one-way clutch inner race to the
transmission case.

Temporarity tighten the 7 fixing bolts.

UNIT REPAIR (JR405E) 7A4-61

31ASSY074



Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-way
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 N






m (17 Ib






ft)


32ASSY007

9. Dish plate, driven plate, drive plate, and retaining plate
(low and reverse brake)

Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.


33ASSY008



34ASSY009



35N-SPG02



Install the N-type spring.

7A4-62 UNIT REPAIR (JR405E)





RTW37AMF0001-X



36ASSY10



Install the retaining plate (4).


37ASSY011



Install the snap ring.


38L&R03



Force compressed air (392 kPa/4.0 kg/cm2) through the
oil passages of the transmission case to check low and
reverse brake operation.
If the low and reverse brake does not operate, check the
seal rings for damage and replace if necessary. Also
check that no parts have been installed out of place.

UNIT REPAIR (JR405E) 7A4-63

39L&R04


249L300003



Measure the clearance between the low and reverse
retaining plate and the snap ring.
If the clearance is out side the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Low and reverse retaining and snap ring clearance:
0.7~1.1 mm (0.028~0.043 in)
Available low and reverse brake retaining plate
thickensses
5.2 mm (0.205 in)
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)

10.Dish plate, drive plate, driven plate, and retaining plate
(2-4 brake)
NOTE:
It is careful in the attachment direction of dish plate (1).
If 2-4 brake clearance measurement is required, it must be
done now.
Brake clearance cannot be measured after the carrier
assembly has been installed.

402-4B08



Install the 2-4 brake dish plate to the transmission case
(plate contact surface).

UNIT REPAIR (JR405E) 7A4-71
Power train
01HUB-H04
Legend
1. O-ring
2. Input shaft
3. Bearing
4. Reverse and high clutch assembly
5. Bearing
6. High clutch hub
7. Bearing race


8. Bearing
9. Front sun gear
10. Bearing race
11. Bearing
12. Carrier and low clutch assembly
13. Bearing
14. Transmission case


Reassembly steps
1. Transmission case
Rotate the transmission case so that the converter housing
installation surfaces are facing up.

02ASSY012

2. Bearing
Install the bearing to the low and one-way clutch inner race.
Refer to the item “Transmission Case ” for more detailed
information.
NOTE:
Apply Vaseline to the bearing to prevent them from failing
during the installation procedure.

7A4-76 UNIT REPAIR (JR405E)

24ASSY047



Install the high clutch hub and the bearing race to the
transmission case.


25R&H42

11.Clutch pack (reverse and high clutch assembly)

Install the bearing (with bearing race) to the clutch pack.
NOTE:







The black side (bearing race) of the bearing must
contact the clutch pack.







Apply Vaseline to the bearing.


26ASSY049



Install the clutch pack and bearing to the transmission
case.



27ASSY051



Install the bearing to the clutch pack.
NOTE:
Apply Vaseline to the bearing.







RTW47ASH000101

Total end play measurement

Install the bearing race (oil pump) to the clutch pack.

Measure the distance (A) between the oil pump
installation surface and the bearing race.

7A4-84 UNIT REPAIR (JR405E)

SERVICE STANDARD
Name BESCO ATF II or ATF III ATF
Quantity L 9.2 – 9.6
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plate / driven plate 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coil 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring
Linear diameter mm (in) 1.2 (0.047)
Number of drive plate / driven plate 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coil 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drive plate / driven plate 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.0236 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in)
5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plate / driven plate 6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)