Transmission ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43



Use a pin punch to drive the manual plate spring pin into
place.


21CASE-AY48

3. Detent spring

Install the detent spring and tighten the fixing bolt to the
specified torque.
Torque: 7 N






m (61 Ib






in)


23CASE-AY53

4. Harness assembly

Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.

Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
Torque: 6 N






m (52 Ib






in)


24ASSY003

5. Low one-way clutch inner race

Install new seal rings to the low one-way clutch inne
r
race.


25ASSY126



Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0004~0.001 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.

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).

7A4-64 UNIT REPAIR (JR405E)

412-4B09



Install the drive plate, driven plate, and the retaining
plate.


422-4B10



432-4B11



442-4B12

11.2
– 4 brake piston and 2 – 4 brake retainer

Install new seal ring to the 2-4 brake piston.

Install the 2-4 brake piston to the 2-4 brake retainer.


452-4B15



Install the 2-4 brake piston and the 2-4 brake retainer to
the transmission case.
Pay close attention to the retainer projection from the
case groove.

UNIT REPAIR (JR405E) 7A4-65

472-4B17



Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Be sure that the spring compressor is perfectly centered
(an off-center special tool will damage the return spring).

Use the spring compressor to force the 2-4 brake
retainer.


482-4B18

NOTE:
To avoid damaging the return spring, apply as little force
as possible to the 2-4 brake retainer.

Install the snap ring.


492-4B22



Force compressed air (392 kPa/4.0 kg/cm2) through the
oil passages of the transmission case to operate and
break-in the 2-4 brake.


502-4B19



Measure the clearance between the 2-4 brake retainer
and the retaining plate.
If the clearance is outside the specified range, replace
the existing brake retainer with a new one of the prope
r
size (thickness).
2 – 4 brake retainer and retaining plate clearance:
1.0~1.4 mm (0.039~0.055 in)
Available 2-4 brake retaining plate thicknesses
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
6.2 mm (0.244 in)
6.4 mm (0.252 in)

Use the spring compressor to release the 2-4 brake.

7A4-68 UNIT REPAIR (JR405E)
1. Bearing and bearing race
Outside diameter Bearing – 46 mm (1.811 in)
Bearing race – 45 mm (1.772 in)
01BRG16








2. Bearing (with bearing race)
Outside diameter
Bearing – 46 mm (1.811 in)

02BRG02


Bearing race (black color) installation direction – Facing the
front of the transmission.



3. Bearing and bearing race
Outside diameter Bearing – 65 mm (2.559 in)
Bearing race – 64 mm (2.520 in)

03BRG04





4. Bearing and bearing race
Outside diameter Bearing – 73 mm (2.874 in)
Bearing race – 72 mm (2.835 in)

04BRG05





5. Bearing (with bearing race)
Outside diameter
Bearing – 53 mm (2.087 in)

05BRG06


Bearing race (black color) installation direction – Facing the
front of the transmission.

UNIT REPAIR (JR405E) 7A4-69
6. Bearing
Outside diameter
Bearing – 53 mm (2.087 in)
06BRG07





7. Bearing and bearing race
Outside diameter Bearing – 78 mm (3.071 in)
Bearing race – 76 mm (2.992 in)

07BRG08





8. Bearing and bearing race
Outside diameter Bearing – 53.4 mm (2.102 in)
Bearing race – 51 mm (2.008 in)

08BRG09





9. Bearing (with bearing race)
Outside diameter
Bearing – 64 mm (2.520 in)

09BRG18


Bearing race (black color) installation direction –Facing the
rear of the transmission.



10.Bearing (with bearing race)
Outside diameter
Bearing – 64 mm (2.520 in)

10BRG17


Bearing race (black color) installation direction –Facing the
front of the transmission.

7A4-70 UNIT REPAIR (JR405E)

AUTOMATIC TRANSMISSION
REASSEMBLY
Assembly cautions

Use your bare hands or vinyl gloves to reassemble the
transmission. Do not use ordinary work gloves (loosen
threads from the gloves may fall into the transmission
and cause problems).

Before installing the drive plates, immerse them in the
recommended automatic transmission fluid (BESCO
ATF II or ATF III). If the drive plate is new, it must be
immersed for at least two hours to ensure oil penetration
and saturation of the facing.


Apply ATF to all sliding and contact surfaces before
assembly. Also apply ATF to seal rings and O-rings.
Assemble the parts carefully to avoid damaging them.

Replace any snap ring that appears worn, bent out o
f
shape, or otherwise damaged.

If any part contacting the transmission case is damaged,
it must be replaced with a new part.

Be careful not to damage the plates during reassembly
(oil leakage from the plate will result).

If you are reusing a seal, remove the old adhesive agen
t
and clean the surface with cleaning oil before applying
the new adhesive agent.

Wait at least two hours after installing the oil seals
before installing the plates.

Do not replace O-rings, snap rings, bearings, and/o
r
bearing races with inferior substitutes.

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.