oil ISUZU TF SERIES 2004 Workshop Manual

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.

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) 7A4-65

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.

7A4-70 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) 7A4-75

192-4B22



Force compressed air (392 kPa/4.0 kg/cm2) through the
transmission case oil passage to 2-4 brake operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing

Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040

Install the front sun gear to the transmission case.


22ASSY042

Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.

7A4-76 UNIT REPAIR (JR405E)

24ASSY047



Install the high clutch hub and the bearing race to the
transmission case.


25R&H42

11.Clutch pack (reverse and high clutch assembly)

Install the bearing (with bearing race) to the clutch pack.
NOTE:







The black side (bearing race) of the bearing must
contact the clutch pack.







Apply Vaseline to the bearing.


26ASSY049



Install the clutch pack and bearing to the transmission
case.



27ASSY051



Install the bearing to the clutch pack.
NOTE:
Apply Vaseline to the bearing.







RTW47ASH000101

Total end play measurement

Install the bearing race (oil pump) to the clutch pack.

Measure the distance (A) between the oil pump
installation surface and the bearing race.

UNIT REPAIR (JR405E) 7A4-77





RTW47ASH000201



Measure the distance (B) between the bearing race
installation surface and the machined surface.

Calculate the total end play using the following formula.
Total end play = distance (A) – distance (B)
If the measured and calculated end play is outside the
specified range, replace the existing bearing race with a
bearing race of the proper size (thickness).
Total end play = 0.25~0.55 mm (0.0098~0.0217 in)
Available oil pump bearing race thicknesses
1.4 mm (0.055 in)
1.6 mm (0.063 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)
2.2 mm (0.087 in)
2.4 mm (0.094 in)





RTW47ASH000201


28ASSY058

12.Input shaft
Install the input shaft.


29PUMP02

13.Oil pump assembly

Install a new O-ring to the outside of the oil pump.

Install the bearing race to the oil pump.
NOTE:
Apply Vaseline to the bearing race.

7A4-78 UNIT REPAIR (JR405E)

30ASSY067



Apply ATF to the O-ring at the outside of the oil pump.

Install the oil pump assembly to the transmission case.


Apply sealing agent (TB1215) to the threaded surfaces
of the 8 fixing bolts and tighten to the specified torque.
Torque: 58 N 


m (43 Ib 


ft)


31ASSY068

14.O-ring
Install a new O-ring to the input shaft.


32ASSY116

15.Converter housing
Install the converter housing and tighten the bolts to the
specified torque. Torque: 53 N 


m (39 Ib 


ft)


33ASSY075

16.Actuator support
Install the actuator support.


34ASSY077

17.Parking pawl, shaft, spring, and spacer
Install the parking pawl, the shaft, the spring, and the
spacer.

7A4-80 UNIT REPAIR (JR405E)

40ASSY091



Push the output shaft into place.


19.Rear extension (2WD) or adapter case (4WD)

Use the oil seal installer to install the oil seal to the rea
r
extension (2WD) or adapter case (4WD).
Oil seal installer:
5-8840-2769-0 (2WD)
5-8840-2770-0 (4WD)

41ASSY096



Install the bearing (with bearing race) to the rear
extension (2WD) or adapter case (4WD).
NOTE:







The black side (bearing race) of the bearing must be
visible.







Apply Vaseline to the bearing.




249L300005



Apply sealing agent (TB1216B) to the rear extension
(2WD) or adapter case (4WD) contact surfaces.



249L300006

Install the rear extension (2WD) or adapter case (4WD)
to the transmission case and tighten the 10 bolts to the
specified torque.
Torque: 53 N 


m (39 Ib 


ft)

7A4-82 UNIT REPAIR (JR405E)
244L300001


21.Oil pan

Install a new gasket and the oil pan.

Tighten the bolts to the specified torque.
Torque: 8 N 


m (69 Ib 


in)

47INH-SW01

22.Inhibitor switch

Secure the inhibitor switch (1) by hand-tightening the 2
bolts.

Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.

Tighten the 2 inhibitor switch bolts to the specified
torque.