transmission oil ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-43

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands.
3. Remove front propeller shaft.(4WD only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
5. Remove the middle exhaust pipe.



RTW37ASH0001

6. Disconnect the transfer harness connectors and the
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
7. Support transfer case with a transmission jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.






P1010010
11. Discinnect the transmission harness connectors
and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.

7A3-48 ON-VEHICLE SERVICE (AW30 –40LE)

11. Install the suspension crossmember.
Torque: 65 N 


m (6.6 kg 


m/48 lb ft)
12. Install filler tube and insert oil level gage.
Torque: 22 N 


m (2.2 kg 


m/16 lb ft)
13. Install select cable by connecting inner cable to
select lever and installing outer cable with bracket.
14. Install the fuel pipe brackets to the transmission. Install the fuel pipe clips with the pipes to the
bracket.





P1010010
15. Connect the transmission harness connectors and
clips.
16. Connect transmission oil cooler pipes to A/T.
Torque: 44 N 


m (4.5 kg



m/33 lb ft)
17. Install oil cooler pipe clamp and bracket to the
converter housing.


18.Tighten oil cooler pipe clamp bolt at the engine
mount side.




P1010024
19. Install the transfer case assembly.(4WD only)

Apply a thin coat of molybdenum disulfide grease
to the input shaft spline as shown in the figure.


260R300001

Install the transfer case assembly.

UNIT REPAIR (AW30–40LE) 7A4–1
TRANSMISSION
CONTENTS
UNIT REPAIR (AW30–40LE)
Major Components (1) ................................... 7A4–3
Major Components (1) and Associated
parts ........................................................... 7A4–3
Disassembly steps...................................... 7A4–3
Components (1) ............................................. 7A4–5
Reassembly ................................................ 7A4–5
Major Components (2) ................................... 7A4–7
Major Componets (2) and Associated
Parts ........................................................... 7A4–7
Disassembly ............................................... 7A4–8
Reassembly ................................................ 7A4–11
Major Components (3) ................................... 7A4–16
Major Components (3) and Associated
Parts ........................................................... 7A4–16
Disassembly ............................................... 7A4–17
Reassembly ................................................ 7A4–25
Diaassembly, Inspection and Reassembly
of minor Components ................................. 7A4–37
Oil Pump ........................................................ 7A4–38
Disassembly View ...................................... 7A4–38
Disassembly ............................................... 7A4–38
Inspection and Repair................................. 7A4–39
Reassembly ................................................ 7A4–41
OD Planetary Gear and OD Direct Clutch
Assembly (C–0).......................................... 7A4–43
Disassembled View .................................... 7A4–43
Disassembly ............................................... 7A4–44
Inspection and Repair................................. 7A4–47
Reassembly ................................................ 7A4–48
OD Support Assembly ................................... 7A4–53
Disassembled View .................................... 7A4–53
Disassembly ............................................... 7A4–53
Inspection and Repair................................. 7A4–54
Reassembly ................................................ 7A4–55
Direct Clutch Assembly (C-2) ........................ 7A4–58
Disassembled View .................................... 7A4–58
Disassembly ............................................... 7A4–59
Inspection and Repair................................. 7A4–60
Reassembly ................................................ 7A4–61
Forward Clutch Asseembly (C-1)................... 7A4–64
Disassembled View .................................... 7A4–64
Disassembly ............................................... 7A4–65
Inspection and Repair................................. 7A4–66
Reassembly ................................................ 7A4–67
Front Planetary Gear ..................................... 7A4–71
Disassembled View .................................... 7A4–71
Disassembly ............................................... 7A4–71
Inspection and Repair................................. 7A4–71
Reassembly ................................................ 7A4–72Planetary Sun Gear and No.1 One-Way
Clutch ......................................................... 7A4–73
Disassembled View .................................... 7A4–73
Disassembly ............................................... 7A4–74
Inspection and Repair ................................. 7A4–74
Reassembly ................................................ 7A4–75
Second Brake Assembly (B–2)...................... 7A4–77
Disassembled View .................................... 7A4–77
Disassembly ............................................... 7A4–77
Inspection and Repair ................................. 7A4–78
Reassembly ................................................ 7A4–78
Rear Planetary Gear Assembly and Output
Shaft ........................................................... 7A4–81
Disassembled View .................................... 7A4–81
Disassembly ............................................... 7A4–82
Reassembly ................................................ 7A4–84
First and Reverse Brake (B–3) ...................... 7A4–87
Disassembled View .................................... 7A4–87
Disassembly ............................................... 7A4–88
Reassembly ................................................ 7A4–89
Transmission Valve Body assembly .............. 7A4–92
Disassembled View .................................... 7A4–92
Disassembly ............................................... 7A4–93
Reassembly ................................................ 7A4–93
Lower Valve Body .......................................... 7A4–96
Cross Section ............................................. 7A4–96
Disassembly ............................................... 7A4–98
Inspection and Repair ................................. 7A4–103
Reassembly ................................................ 7A4–104
Upper Valve Body .......................................... 7A4–109
Cross Section ............................................. 7A4–109
Disassembly ............................................... 7A4–111
Inspection and Repair ................................. 7A4–115
Reassembly ................................................ 7A4–116
Transmission Case ........................................ 7A4–121
Disassembled View .................................... 7A4–121
Disassembly ............................................... 7A4–121
Reassembly ................................................ 7A4–122
Torque Converter........................................... 7A4–124
Inspection and Repair ................................. 7A4–124
Adapter Housing (4
4)................................. 7A4–125
Disassembled View .................................... 7A4–125
Disassembly ............................................... 7A4–125
Reassembly ................................................ 7A4–125
Ex tension Housing (4
2) ............................. 7A4–126
Disassembled View .................................... 7A4–126
Disassembly ............................................... 7A4–126
Reassembly ................................................ 7A4–126
Main Data and Specifications ........................ 7A4–128

UNIT REPAIR (AW30–40LE) 7A4–3
Major Components (1)
Major Components (1) and Associated parts
RTW 37A M F00 0601
E nd O FCallo ut
Disassembly steps
1. Remove the torque converter.
2. Remov e the select lev er.
Legend
(1) Torque converter
(2) Select lever
(3) Neutral start switch (Mode switch)
(4) Elbow
(5) Oil temperature sensor
(6) Breather hose
(7) Input revolution sensor(8) Output revolution sensor (4
4)
(9) Output revolution sensor (4
2)
(10) Speedometer sensor, speedometer driven gear
and plate (4
2)
(11) Extension housing (4
2)
(12) Adapter housing (4
4)
(13) Transmission assembly

7A4–4 UNIT REPAIR (AW30–40LE)
3. Remove the neutral start switch (Mode switch).
Unstake the lock washer.
Remove the nut and bolt, and then remove the
neutral start switch.
Remove the lock washer.
RTW 37BSH00 010 1
4. Remove the two elbows from transmission case.
24 0RY 0 000 1
5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4
4).
9. Remove the output revolution sensor (4
2).
10. Remove the speedometer sensor, speedometer
driven gear and plate (4
2).
11. Remove the ex tension housing (4
2).
12. Remove the adapter housing (4
4).13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fix ture: J–37227
Holding fix ture base: J–3289–20
RUW3 7A SH00 3001

UNIT REPAIR (AW30–40LE) 7A4–5
Components (1)
Reassembly
1. Install a new gasket and the ex tension housing
(4
2) to the transmission case.
Torque: 36 N·m (27 Ib ft)
2. Install the speedometer driven gear, plate, and
speedometer sensor (4
2).
To r q u e :
Plate bolt – 15 N·m (11 Ib ft)
Speedometer sensor – 25 N·m (18 Ib ft)
3. Install the adapter housing (4
4).
Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
24 1RY 0 002 0
Apply liquid gasket (TB1281–B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
Install the adapter housing to the transmission
case.
Torque: 34 N·m (25 Ib ft)
4. Install the neutral start switch.
Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
Install the lock washer and nut.
Torque: 7 N·m (61 Ib in)Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (113 Ib in)
Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW1 7A SH01 3601
5. Install the oil temperature sensor to the transmission
case.
Torque: 15 N·m (11 Ib ft)
RUW3 7A SH00 4001

7A4–8 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove the six bolts and remove the converter
housing.
2 40R20 002 2
2. Remove the oil pan.
NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove the nineteen bolts.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J–37228
RUW 37A SH00 290 1
3. Ex amine particles in oil pan.
Remove the magnet and use it to collect any
steel chips. Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear
24 0RY 0 0008
4. Remove the oil strainer assembly.
Remove four bolts holding the oil strainer.
24 4RY 0 0003

7A4–10 UNIT REPAIR (AW30–40LE)
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C–2).
Remove accumulator pistons and springs from
transmission case.
24 0RY 0 001 0
10. Applying compressed air to the oil hole, remove the
B–0 accumulator piston and spring.
24 0RY 0 0011
11. Remove the C–0 accumulator piston.
24 0RY 0 0012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4
4).
Remove the snap ring from the output shaft.
Remove the rotor and key.
2 47R20 0002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4
2).
Remove the snap ring from the output shaft.
Remove the speedometer sensor drive gear, and
ball.

7A4–12 UNIT REPAIR (AW30–40LE)
5. Install the second brake drum gasket.
Install a new second brake drum gasket to the
transmission case.
24 0RY 0 001 3
6. Individual piston operation inspection.
Check for the sound of operation while injecting
compressed air into the oil hole indicated in the
figure.
24 0RY 0 001 4
E nd OFCa llou t
NOTE: When inspecting the direct clutch, check with
the C–0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the parts.7. Install the accumulator pistons.
Coat the O–ring with ATF and install it to the
piston.
Install the three springs and four accumulator
pistons to the bore as shown in th figure.
24 0RY 0 0027
mm (in)
Legend
(1) OD direct clutch
(2) Direct clutch
(3) Forward clutch
(4) OD brake
(5) Second coast brake
(6) Second brake
(7) First and reverse brake
(A) C–0 Accumulator piston hole
Piston Outer diameter Height
B–2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C–2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B–0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C–0 29.8 mm (1.173 in) 44.0 mm (1.732 in)
Spring Free length Outer
diameterColor
B–2 74.6 (2.93) 19.7 (0.78) BROWN
C–2
(Outer)68.5 (2.7) 20.2 (0.80) BLUE
C–2 (Inner) 42.1 (1.658) 14.7 (0.579) PINK
B–0 63.6 (2.504) 16.0 (0.630) RED
C–0
(Outer)74.6 (2.937) 20.9 (0.823) ORANGE
C–0 (Inner) 46.0 (1.811) 14.0 (0.551) YELLOW

UNIT REPAIR (AW30–40LE) 7A4–15
12. Install the oil pan.
Install two magnets in oil pan.
Remove any gasket material and be careful not to
drop oil on the contacting surfaces of the
transmission case and oil pan.
Apply liquid gasket (TB1281 or its equivalent) to the
oil pan as shown in the figure.
NOTE: Install the oil pan as soon as the seal gasket is
applied.
24 0RY 0 001 9
Install and tighten the nineteen bolts.
24 0RY 0 002 0
Torque: 7.4 N·m (65lb in)