ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-47
Free length – 36.4 mm (1.433 in)
Linear diameter – 1.2 mm (0.047 in)


21C&L-SUB31

Reassembly steps
Coat the parts with ATF before installing them.
1. Bearing
Install the bearing into the low clutch drum.


22C&L-SUB30

2. Snap ring
Install the snap ring to the low clutch drum.


23C&L-SUB28

3. Low one-way clutch
Install the low one-way clutch to the low clutch drum.


24C&L-SUB33

NOTE:
The flanged side of the low one-way clutch must face the
outside.

7A4-48 UNIT REPAIR (JR405E)

25C&L-SUB27

4. Side plate
Install the side plate.


26C&L-SUB26

5. Snap ring
Install the snap ring to the low clutch drum.


27C&L-SUB58



Attach the low one-way clutch inner race to the low
clutch drum in the opposite direction of normal position.

Rotate the one-way clutch inner race clockwise. I
t
should turn smoothly with little resistance.

Rotate the low one-way clutch inner race
counterclockwise.
It should immediately lock (rotation is impossible).
If it does not, check the low one-way clutch installation
direction.
Inspect and replace the low one-way clutch if required.

Remove the low one-way clutch inner race.

Reverse the low clutch drum.


28C&L-SUB32

6. Low clutch piston

Install new seal rings to the low clutch piston.

UNIT REPAIR (JR405E) 7A4-49

29C&L-SUB22



Install the low clutch piston to the low clutch drum.


30C&L-SUB21

7. Return spring
Install the return spring to the low clutch piston.


31C&L-SUB20

8. Cancel cover

Carefully center the cancel cover and install it.
NOTE:
If the cancel cover is not centered, the cover outside seal
ring gum will be forced into the low clutch piston area
where it will be damaged.

32C&L-SUB18



Install the spring compressor to the low clutch.
Spring compressor: 5-8840-2759-0


33C&L-SUB19

9. Snap ring

Use the spring compressor to carefully force the cancel
cover down.
NOTE:
To avoid damage to the return spring, use only as much
force as is required to press the cancel cover into place.

Install new snap ring to the low clutch drum.

7A4-50 UNIT REPAIR (JR405E)

34C&L-SUB15

10.Dish plate, drive plate, driven plate, and retaining plate
Install the low clutch dish plate (1), the 2 mm thick driven
plate (2), the 7 drive plate (3), the other 6 driven plates (4),
and the retaining plate (5).
NOTE:
Dish plate side with the identification mark must face the
driven plate.

248L300006

11.Snap ring
Install the snap ring to the low clutch drum.

NOTE:
It is careful in the attachment direction of dish plate.

35C&L-SUB38



36CLEAR06


Inspection

Insert the low one-way clutch inner race to the low clutch
drum.

Force compressed air (392 kPa/4.0 kg/cm
2) through the
oil passages of the low one-way clutch inner race to
check low clutch operation.
If the low clutch does not operate, the seal rings may be
damaged or the parts may have been installed in the
wrong order.

Measure the clearance between the low clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing plate with a new plate of the proper size
(thickness).
Low clutch retaining plate and snap ring clearance:
0.9~1.3 mm (0.035~0.051 in)
Available low clutch retaining plate thicknesses
3.8 mm (0.150 in)
4.0 mm (0.157 in)

UNIT REPAIR (JR405E) 7A4-51
248L300007

4.2 mm (0.165 in)
4.4 mm (0.173 in)
4.6 mm (0.181 in)
4.8 mm (0.189 in)

37C&L-SUB40

12.Bearing race
13.Rear internal gear
14.Bearing Install the bearing race and the bearing to the rear internal
gear.
NOTE:
Apply Vaseline to the fitting surfaces of the rear internal
gear to prevent the bearing race and the bearing from
falling during the installation process.


38C&L-SUB43


39C&L-SUB60

Install the rear internal gear to the low clutch drum.

7A4-52 UNIT REPAIR (JR405E)

40C&L-SUB46

15.Bearing race
16.Rear carrier
17.Bearing Install the bearing race and the bearing to the rear carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the rear carrier to
prevent the bearing race and the bearing from falling
during the installation process.


41C&L-SUB49


42C&L-SUB61

Install the rear carrier to the low clutch drum.


43C&L-SUB07

18.Rear sun gear
Install the rear sun gear to the low clutch drum.


44C&L-SUB52

19.Bearing (with bearing race)
20.Front carrier Install the bearing (with bearing race) to the front carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the front carrier to
prevent the bearing from falling during the installation
process.

UNIT REPAIR (JR405E) 7A4-53

45C&L-SUB04

21.Snap ring

Install the front carrier to the low clutch drum.

Install the snap ring to the low clutch drum.

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

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.

7A4-56 UNIT REPAIR (JR405E)

05CASE-AY30

2. Parking rod

Use a pin punch to force out the parking rod spring pin.


06CASE-AY37



Rotate the manual plate as you pull the parking rod free.


08CASE-AY45

3. Detent spring
Remove the fixing bolt and the detent spring.


09CASE-AY28

4. Manual shaft and manual plate

Remove the manual shaft spring pin.


10CASE-AY21



Remove the manual shaft together with the manual
plate.