Transmission ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-3
Disassembly steps
1. Torque converter

Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.

Draining the ATF from the torque converter.


01ASSY101

2. Turbine sensor and speed sensor

Remove the turbine sensor from the transmission case.



02ASSY103



Remove the speed sensor from the transmission case.



03ASSY106

3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.


240L300002

4. Oil pan

Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0

Remove the drain plug from the oil pan and drain the
ATF from the oil pan.

Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.

Rotate the automatic transmission so that the oil pan is
facing up.

Remove the 19 bolts and the oil pan.

7A4-6 UNIT REPAIR (JR405E)

10ASSY116

6. Converter housing

Position the automatic transmission so that the
converter housing is facing up.

Remove the 8 bolts and the converter housing.



11ASSY068

7. O-ring
Remove the O-ring from the input shaft.


12ASSY067

8. Oil pump assembly and bearing race

Remove the 8 bolts.

Use a slide hammer to remove the oil pump assembly
from the transmission case.
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.

Remove the bearing race from the oil pump assembly.

Inspect the bearing race surfaces for damage.


14ASSY057

9. Input shaft
Pull the input shaft free.


15ASSY049

10.Clutch pack (Reverse and high clutch assembly) and
bearing

Pull the clutch pack free.

Remove the bearing from the clutch pack.

UNIT REPAIR (JR405E) 7A4-7

16ASSY047

11.High clutch hub, bearing, and bearing race

Remove the clutch hub, bearing (with bearing race),
and the bearing race.

Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.

Inspect the bearing race surfaces for damage.



17ASSY040

12.Front sun gear, bearing, and bearing race

Remove the bearing, the front sun gear, and the bearing
race.

Remove the bearing and the bearing race from the fron
t
sun gear.

Inspect the bearing race surfaces for damage.


19ASSY113

13.2-4 brake retainer

Remove the brake seal ring and the sleeve.



23ASSY030



Attach the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0



24ASSY029



Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.

Remove the spring compressor.

7A4-8 UNIT REPAIR (JR405E)

25ASSY019



Remove the 2-4 brake retainer and return spring.



26ASSY026

14.Carrier assembly (Carrier and low clutch assembly),
bearing, bearing race, and 2 – 4 brake assembly

Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.

Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.



27U-SPG02



Remove the 3 brake springs from the transmission case.



28L&R06

15.Low and reverse brake

Remove the snap ring.

Pull the low and reverse brake free.


16.Rear extension (2WD) or Adapter case (4WD)

Rotate the transmission case so that the oil pan opening
is facing up.

Remove the 10 bolts and the rear extension (2WD) o
r
the adapter case (4WD).

UNIT REPAIR (JR405E) 7A4-9

29ASSY091

17.Output shaft

Pull the output shaft from the transmission case.


30ASSY089



Remove the bearing (with bearing race) from the
transmission case.


31ASSY124

18.Parking pawl, shaft, spring, and spacer
Remove the parking pawl, shaft, spring and spacer from the
transmission case.


36ASSY075

19.Actuator support
Remove the actuator support from the transmission case.


37ASSY074

20.Low one-way clutch inner race and bearing

Loosen the 7 bolts securing the low one-way clutch inne
r
race.
NOTE:
Loosen the bolts a little at a time as uniformly as possible
to prevent the inner race from tilting and becoming
jammed.

Remove the 6 bolts. Support the low one-way clutch
inner race with your hand and remove the final bolt.

7A4-10 UNIT REPAIR (JR405E)

39ASSY006



Remove the bearing and the low one-way clutch inner
race from the transmission case.

Remove the bearing from the low one-way clutch inne
r
race.


40ASSY005

21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.


41L&R02

22.Low and reverse brake piston

Force compressed air (329kPa/4.0kg/cm
2) through the
transmission case oil passages.


42ASSY004



Remove the low and reverse brake piston from the
transmission case.

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.

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)

7A4-58 UNIT REPAIR (JR405E)
Free length = 22.3 mm (0.878 in)
Linear diameter = 1.1 mm (0.043 in)


12CASE-AY06

Reassembly steps
1. Oil seal, manual shaft, and manual plate

Use the oil seal installer to force the manual plate oil
seal into place.
Oil seal installer: 5-8840-2758-0


14CASE-AY21



Install the manual shaft together with the manual plate.


15CASE-AY26



Drive the spring pin into the transmission case.


16CASE-AY37

2. Parking rod

Rotate the manual plate while installing the parking rod.