transmission oil ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–17
Disassembly
1. Remove seven bolts fix ing the oil pump to the
transmission case.
Remove the oil pump.
24 1RY 0 000 3
2. Remove race from oil pump.
24 1RY 0 000 2
3. Remove the overdrive planetary gear and overdrive
direct clutch with thrust needle bearing from the
transmission case.
25 2L10 0001
4. Remove the race from OD planetary gear.
25 2L10 0017

UNIT REPAIR (AW30–40LE) 7A4–21
14. Using snap ring pliers, remove the snap ring.
24 8RY 0 000 6
15. Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
24 8RY 0 000 7
16. Remove the direct clutch and forward clutch from
the transmission case.
24 8RY 0 0008
17. Remove the E-ring from the pin.
Remove the pin from the brake band.
24 8RY 0 0009

UNIT REPAIR (AW30–40LE) 7A4–31
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
A ssembled bearing and race diameter
(Reference)
24 8RY 0 002 5
20. Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
RUW 37A SH00 440 1
E nd OFCa llou t
21. Coat two new oil seals with ATF and install them to
the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
24 8RY 0 0027
22. Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod
as shown in the figure.
24 8RY 0 0005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 11 4 p s i )
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in) Inside Outside
Bearing
and race33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod

7A4–32 UNIT REPAIR (AW30–40LE)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 000 4
23. Coat the race with petroleum jelly and install it onto
the overdrive support assembly.
Race diameter (Reference)
25 2RY 0 000 7
24. Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.
25 2RY 0 0005
25. Using snap ring pliers, install the snap ring as
shown in the figure.
25 2RY 0 0008
Inside Outside
Race 36.7 mm (1.44 in) 50.8 mm (2.00 in)

7A4–36 UNIT REPAIR (AW30–40LE)
34. Install the overdrive planetary gear and direct clutch.
2 52L10 000 1
35. Coat the assembled bearing and race with
petroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
2 52L10 001 8
36. Coat the race with petroleum jelly and install it onto
the oil pump.
Race diameter (Reference)
25 2RY 0 0014
37. Coat the O-ring with ATF and install it around the
pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CA UTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N·m (16 lb ft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.
24 1RY 0 0003
Inside Outside
Bearing
and race28.9 mm (1.138 in) 50.2 mm (1.976 in)
Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

UNIT REPAIR (AW30–40LE) 7A4–121
Transmission Case
Disassembled View
24 9RY 0 0001
E nd O FCallo ut
Disassembly
1. Using a chisel, cut off the spacer and remove it from
the shaft.
24 9RY 0 0002
Legend
(1) Spacer
(2) Pin
(3) Manual valve lever shaft(4) Manual valve lever
(5) Oil seal
(6) Oil seal

7A4–122 UNIT REPAIR (AW30–40LE)
2. Using a punch, drive out the pin.
24 9RY 0 000 3
3. Pull the manual valve lever shaft out through the
case by the threads.
4. Take out the manual valve lever.
5. Using a screwdriver, remove the oil seals.
24 9RY 0 000 4
Reassembly
1. Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : J–37232–2
RTW3 7A SH00 0701
2. Assemble a new spacer to the manual valve lever.
3. Install the manual valve lever shaft to the
transmission case through the manual valve lever
by the threads.
24 9RY 0 0005

CONSTRUCTION AND FUNCTION 7A1-1

SECTION 7A1
CONSTRUCTION AND FUNCTION
TABLE OF CONTENTS
PAGE
DESCRIPTION ..............................................................................................................................7A1- 3
CONSTRUCTION ....................................................................................................................7A1- 3
MAIN DATA AND SPECIFICATION .....................................................................................7A1- 4
NUMBER PLATE LOCATION ...............................................................................................7A1- 5
ELECTRONIC CONTROL COMPONENTS LOCATION ..................................................7A1- 6
TRANSMISSION CONTROL UNIT (TCM) PERIPHERAL CIRCUIT ..............................7A1- 7
STRUCTURE AND FUNCTION OF COMPONENT ...........................................................7A1- 8
TORQUE CONVERTER (WITH LOCK-UP FUNCTION) ..................................................7A1- 8
OIL PUMP .................................................................................................................................7A1- 9
INPUT SHAFT ..........................................................................................................................7A1- 10
OUTPUT SHAFT ......................................................................................................................7A1- 10
GEAR SHIFTING MECHANISM ............................................................................................7A1- 10
CONTROL VALVE ...................................................................................................................7A1- 14
OIL PASSAGE .........................................................................................................................7A1- 19
PARKING FUNCTION .............................................................................................................7A1- 20
INHIBITOR SWITCH ...............................................................................................................7A1- 21
TURBINE SENSOR .................................................................................................................7A1- 22
SPEED SENSOR .....................................................................................................................7A1- 22
THROTTLE POSITION SENSOR (TPS) .............................................................................7A1- 23
ENGINE SPEED SENSOR (=TDC SENSOR) ....................................................................7A1- 23
BRAKE SWITCH ......................................................................................................................7A1- 24
MODE SELECT SWITCH .......................................................................................................7A1- 24
TRANSMISSION CONTROL MODULE (TCM) ..................................................................7A1- 25
CONTROL MECHANISM ............................................................................................................7A1- 26
CONTENT OF FUNCTION AND CONTROL ......................................................................7A1- 26
CONTROL ITEM, INPUT AND OUTPUT .................................................................... 7A1- 29
LINE PRESSURE CONTROL ..................................................................................... 7A1- 30

CONSTRUCTION AND FUNCTION 7A1-3

DESCRIPTION
CONSTRUCTION



































1 Converter Housing 6 Low Clutch 11 Oil Pump
2 Torque Converter 7 Low & Reverse Brake 12 Control Valve
3 High Clutch 8 Output Shaft 13 Low One-way Clutch
4 Reverse Clutch 9 Extension Housing 14 Parking Gear
5 2-4 Brake 10 Input Shaft

Figure 1. Construction of Automatic Transmission

The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module
(TCM). There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift
Control: DESC) using a duty cycle type solenoid, which ensures high shift quality.
This transmission also controls learning and constantly checks the time of each clutch and brake required for
the speed change to match this time with the target value for the optimum speed change.

The TCM will automatically select the most appropriate shift points and lock-up points depending on the
throttle opening angle, the vehicle speed and the vehicle load.
If any trouble arises in the vehicle sensor, throttle sensor, solenoid, etc., the fail-safe control function is
activated to keep the running performance.
Problems with the sensors, the solenoids can be quickly detected with the self diagnosis procedure described
in this manual.

The JR405E automatic transmission consists of the torque converter, the oil pump, the input shaft, the out put
shaft, the planetary gears and the control valve.
The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two
multiple plate brakes and a one-way clutch.
2WD
4WD