oil ISUZU TF SERIES 2004 Workshop Manual

7A4-34 UNIT REPAIR (JR405E)

08R&H36

8. High clutch piston
9. Reverse clutch piston
Install the reverse and high clutch drum to the oil pump.

Force compressed air into the oil pump oil channels.

Remove the high clutch piston and the reverse clutch
piston.


09R&H37



12R&H39

10.Seal ring (high clutch)
Remove the 2 seal rings from the high clutch piston.

13R&H38

11.Seal ring (reverse clutch)
Remove the 2 seal rings from the reverse clutch piston.




Inspection
Drive plate

Measure the drive plate facing thickness at 3 points.

Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)

UNIT REPAIR (JR405E) 7A4-35
Return spring
Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2

Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)


10R&H40

Reverse clutch piston

Apply compressed air (392 kPa/4.0 kg/cm
2) to the
reverse clutch piston from the outside to the inside.
The flow of air should be blocked.


11R&H44



Apply compressed air (392 kPa/4.0 kg/cm2) to the
reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.


12R&H39

Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.

7A4-36 UNIT REPAIR (JR405E)

13R&H38

2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.




RTW47ASH000601
As shown in a figure, oil seal lip is attached.

14R&H32

3. Reverse clutch piston
Install the reverse clutch piston to the reverse and high
clutch drum.


15R&H31

4. High clutch piston
Install the high clutch piston to the reverse clutch piston.


16R&H33

5. Return spring
Install the return spring to the high clutch piston.

7A4-38 UNIT REPAIR (JR405E)

21R&H21

10.Dish plate, drive plates, driven plates, and retaining
plate Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).

248L300003

11.Snap ring
Install the snap ring.

NOTE:
If is careful in the attachment direction of dish plate (1).

22R&H35



Install the reverse and high clutch drum to the oil pump
assembly.

Force compressed air (392 kPa/4.0 kg/cm
2) through the
oil pump oil passages to check high clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


23CLEAR02



Measure the clearance between the high clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)

UNIT REPAIR (JR405E) 7A4-39
248L300004

5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)




24R&H34


Force compressed air (392 kPa/4.0 kg/cm2) through the
oil pump oil passages to check reverse clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.

UNIT REPAIR (JR405E) 7A4-45

30C&L-SUB21

15.Return spring
Remove the return spring.


15C&L-SUB38

16.Low clutch piston

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

Force compressed air through the oil passages of the
low one-way clutch inner race to remove the low clutch
piston.


29C&L-SUB22



16C&L-SUB25

17.Snap ring

Raise the low one-way clutch side.

Remove the low one-way clutch snap ring.


17C&L-SUB27

18.Side plate
Remove the side plate.

7A4-46 UNIT REPAIR (JR405E)

18C&L-SUB28

19.Low one-way clutch
Remove the low one-way clutch.

19C&L-SUB29

20.Snap ring
Remove the snap ring from the low clutch drum.

20C&L-SUB31

21.Bearing
Remove the bearing.



Inspection
Drive plate

Measure the drive plate facing thickness at 3 points.

Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)
Return spring

Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 9.9

Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 9.7 mm (0.382 in)

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)

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) 7A4-57

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)