brake ISUZU TF SERIES 2004 Workshop Manual

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)

7A4-60 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.

UNIT REPAIR (JR405E) 7A4-61

31ASSY074



Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-way
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 N






m (17 Ib






ft)


32ASSY007

9. Dish plate, driven plate, drive plate, and retaining plate
(low and reverse brake)

Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.


33ASSY008



34ASSY009



35N-SPG02



Install the N-type spring.

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.

7A4-72 UNIT REPAIR (JR405E)

03ASSY013

3. Carrier and low clutch assembly
Install the carrier and low clutch assembly to the
transmission case.
NOTE:
Do not allow the low clutch drum end to protrude beyond
the 2-4 brake plate contact surface (transmission case).


04ASSY014

4. Bearing
Install the bearing to the carrier and low clutch assembly.


05ASSY015

5. Driven plate, drive plate, retaining plate, and dish plate
(2 – 4 brake)
Install the 2-4 brake 5 driven plate (1), 5 drive plates (2),
retaining plate (3), and dish plate (4) in that order.
NOTE:







The thickest driven plate (5.6 mm) must be installed
at the bottom (transmission case plate surface).







Dish plate side with the identification mark must
face the retaining plate.


06ASSY016



07ASSY017

UNIT REPAIR (JR405E) 7A4-73

08ASSY018






RTW47ASH000401



09U-SPG2

6. 2
– 4 brake spring
Install the 2-4 brake springs (3) to the transmission case.





248L300009

7A4-74 UNIT REPAIR (JR405E)

10ASSY019

7. Return spring and 2
– 4 brake retainer

Align the transmission case groove and the 2-4 brake
retainer projection.

Install the return spring and the 2-4 brake retainer.

11ASSY028



12ASSY029

Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Carefully center the spring compressor to prevent damage
to the return spring.

Push the 2-4 brake retainer into place.
NOTE:
Do not push the brake retainer too far.
Damage to the return spring will result.

Install the snap ring.


14ASSY031



17ASSY113

8. Sleeve and seal ring

Install the new sleeve and seal ring to the transmission
case.