clutch ISUZU TF SERIES 2004 Workshop Manual

7A4–30 UNIT REPAIR (AW30–40LE)
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.
24 7RY 0 001 7
18. Coat the bearing and race with petroleum jelly and
install them onto the ring gear.
Bearing and race diameter (Reference)
24 7RY 0 001 9
19. Install the assembled direct clutch, forward clutch
and front planetary ring gear into the transmission
case.
24 7RY 0 0018
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 in)
If the values are nonstandard, check for an
improper installation.
24 8RY 0 0024
Inside Outside
Bearing 35.15 mm (1.384 in) 53.65 mm (2.112 in)
Race 35.15 mm (1.384 in) 53.65 mm (2.112 in)

UNIT REPAIR (AW30–40LE) 7A4–31
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
A ssembled bearing and race diameter
(Reference)
24 8RY 0 002 5
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.
RUW 37A SH00 440 1
E nd OFCa llou t
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.
24 8RY 0 0027
22. Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod
as shown in the figure.
24 8RY 0 0005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 11 4 p s i )
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in) Inside Outside
Bearing
and race33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod

7A4–36 UNIT REPAIR (AW30–40LE)
34. Install the overdrive planetary gear and direct clutch.
2 52L10 000 1
35. Coat the assembled bearing and race with
petroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
2 52L10 001 8
36. Coat the race with petroleum jelly and install it onto
the oil pump.
Race diameter (Reference)
25 2RY 0 0014
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.
CA UTION:
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 N·m (16 lb ft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.
24 1RY 0 0003
Inside Outside
Bearing
and race28.9 mm (1.138 in) 50.2 mm (1.976 in)
Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

UNIT REPAIR (AW30–40LE) 7A4–43
OD Planetary Gear and OD Direct Clutch Assembly (C–0)
Disassembled View
RTW 37A M F00 0701
E nd O FCallo ut
Legend
(1) OD direct clutch assembly
(2) OD planetary gear assembly
(3) Thrust bearing
(4) Snap ring
(5) Flange, disk and plate
(6) Snap ring
(7) Piston return spring
(8) OD direct clutch piston
(9) O-ring(10) Race and bearing asm
(11) Snap ring
(12) Ring gear flange
(13) OD planetary ring gear
(14) Race
(15) Snap ring
(16) Retaining plate
(17) OD one-way clutch
(18) Thrust washer

7A4–44 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of one-way clutch.
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW 37A SH00 450 1
2. Remove OD direct clutch assembly from OD
planetary gear assembly.
2 52L10 000 4
3. Then remove thrust bearing with the race from OD
direct clutch drum.4. 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 0005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
25 2L10 0016

UNIT REPAIR (AW30–40LE) 7A4–45
5. Remove snap ring from clutch drum.
2 52L10 000 6
6. Remove flange, two discs and two plates.
7. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–23327–1
2 52L10 000 7
8. Remove piston return spring
9. Remove the OD direct clutch piston with O-ring.
Place the oil pump onto the torque converter and
then place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand,
apply compressed air to the oil pump to remove
the OD direct clutch piston.Remove the OD direct clutch piston.
25 2L10 0008
10. Remove two O–rings from piston.
11. Remove bearing and race from OD planetary ring
gear.
RTW4 6BSH00 0301

7A4–46 UNIT REPAIR (AW30–40LE)
12. Remove snap ring.
25 2RY 0 002 2
13. Remove ring gear flange from OD planetary ring
gear.
25 2RY 0 002 3
14. Remove the Race.15. Remove snap ring, using screwdriver.
25 2RY 0 0024
16. Remove retaining plate from OD planetary gear.
25 2RY 0 0025
17. Remove OD one-way clutch with outer race.
25 2RY 0 0026

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

7A4–48 UNIT REPAIR (AW30–40LE)
5. Check OD planetary gear bushing.
Using a dial indicator, measure the inside diameter
of replace the OD planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.4437 in)
If the inside diameter is greater than the maximum,
replace the OD planetary gear.
25 2RY 0 003 1
Reassembly
1. Install the thrust washer to the OD planetary gear,
facing the grooved side upward.
25 2RY 0 003 2
2. Install the one-way clutch into the outer race, with
the flanged side of the one-way clutch facing
upward.
25 2RY 0 0033
3. Install OD one-way clutch with outer race to
overdrive planetary gear.
25 2RY 0 0026