217 ISUZU TF SERIES 2004 Owner's Manual

7B1-96 MANUAL TRANSMISSION

Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the ball bearing(3).
226RW216
4. Remove needle bearing (4) and top block ring (5),
mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the
mainshaft snap ring (6).

226RS008

6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
Disassemble the synchronizer assembly.
226RW217

Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
8. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RW218

TRANSFER CONTROL SYSTEM 7D1-23
Parts Location (RHD)





RTW48AXF021701&RTW48AXF021801

7A4–120 UNIT REPAIR (AW30–40LE)
NOTE: Make sure eight retainers are installed correctly
2 43R20 005 4
17. Install the two types of check balls(1) to the valve
body.
Number of check ball : 11
RUW 37A SH00 480 1
Check ball Diameter
(A) Rubber ball 5.535 mm (0.2179 in
(B) Rubber ball 6.35 mm (0.2500 in

DIAGNOSIS (JR405E) 7A2-147
SHIFT POINT CHART
D Range
Normal Mode Power Mode 4L Mode
Gear Throttle
Position
Velocity (km/h) Output Shaft
Speed (rpm)
Velocity (km/h) Output Shaft
Speed (rpm)
Velocity (km/h) Output Shaft
Speed (rpm)
1
2 50%25-3127-33 93029-3531-37105428-34 30-361023
100%36-4237-43 127136-4238-44127132-38 34-401147
2
3 50%46-5249-55 161255-6158-64189152-58 55-611798
100%75-8179-85 254275-8179-85254267-73 71-772294
3
4 50%80-8684-90 269783-8988-94282180-86 84-902697
100%118-124125-131 3967118-124125-1313967107-113 113-1193595
4
3 0%27-3329-35 99227-3329-3599227-33 29-35992
50%52-5855-61 179870-7674-80238767-73 71-772294
100%102-108108-114 3440102-108108-114344093-99 98-1043130
3
2 0%6-126-12 2796-126-122796-12 6-12279
50%28-3430-36 102344-5047-53155043-49 46-521488
100%61-6764-70 207761-6764-70207756-62 59-651922
2
1 0%6-126-12 2796-126-122796-12 6-12279
50%9-1510-16 40318-2419-2568217-23 18-24651
100%27-3329-35 99227-3329-3599225-31 27-36930
Axle Gear Ratio 4.300 4.300 4.300 4.300 4.300 4.300
Tire Radius 0.349 0.368 0.349 0.368 0.349 0.368

3 Range
Normal Mode Power Mode 4L Mode
Gear Throttle
Position
Velocity (km/h) Output Shaft
Speed (rpm)
Velocity (km/h) Output Shaft
Speed (rpm)
Velocity (km/h) Output Shaft
Speed (rpm)
1
2 50%25-3127-33 93029-3531-37105428-34 30-361023
100%36-4238-44 127136-4238-44127132-38 34-401147
2
3 50%46-5249-55 161255-6158-64189152-58 55-611798
100%75-8179-85 254275-8179-85254267-73 71-772294
4
3 0%118-124125-131 3967118-124125-1313967107-113 113-1193595
50%118-124125-131 3967118-124125-1313967107-113 113-1193595
100%118-124125-131 3967118-124125-1313967107-113 113-1193595
3
2 0%6-126-12 2796-126-122796-12 6-12279
50%28-3430-36 102344-5047-53155043-49 45-511488
100%61-6764-70 207761-6764-70207757-63 59-651922
2
1 0%6-126-12 2796-126-122796-12 6-12279
50%9-1510-16 40318-2419-2568217-23 18-24651
100%27-3329-35 99227-3329-3599225-31 27-33930
Axle Gear Ratio 4.300 4.300 4.300 4.300 4.300 4.300
Tire Radius 0.349 0.368 0.349 0.368 0.349 0.368

UNIT REPAIR (JR405E) 7A4-77





RTW47ASH000201



Measure the distance (B) between the bearing race
installation surface and the machined surface.

Calculate the total end play using the following formula.
Total end play = distance (A) – distance (B)
If the measured and calculated end play is outside the
specified range, replace the existing bearing race with a
bearing race of the proper size (thickness).
Total end play = 0.25~0.55 mm (0.0098~0.0217 in)
Available oil pump bearing race thicknesses
1.4 mm (0.055 in)
1.6 mm (0.063 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)
2.2 mm (0.087 in)
2.4 mm (0.094 in)





RTW47ASH000201


28ASSY058

12.Input shaft
Install the input shaft.


29PUMP02

13.Oil pump assembly

Install a new O-ring to the outside of the oil pump.

Install the bearing race to the oil pump.
NOTE:
Apply Vaseline to the bearing race.

UNIT REPAIR (JR405E) 7A4-85

SERVICE STANDARD (Cont’d)
Number of coil 4.8
Outside diameter mm (in) 11.2 (0.441)
Free length mm (in) 22.3 (0.878)
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drive / 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 retaining plate clearance mm (in) 1.0 – 1.4 (0.039 – 0.055)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
6.0 (0.236)
6.2 (0.244)
Available 2-4 brake retaining plate thickness mm (in)
6.4 (0.252)
Number of coil 10.2
Outside diameter mm (in) 6.9 (0.272)
Free length mm (in) 22.5 (0.886)
2-4 brake
Return spring
Linear diameter mm (in) 1.1 (0.043)
Output shaft Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Total end play mm (in) 0.25 – 0.55 (0.0098 – 0.0217)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
2.2 (0.087)
Total end play
Available oil pump bearing race thickness mm (in)
2.4 (0.094)
Torque converter end play mm (in) 67.0 (2.638)