piston ISUZU TF SERIES 2004 Workshop Manual

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
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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

7A4–16 UNIT REPAIR (AW30–40LE)
Major Components (3)
Major Components (3) and Associated Parts
24 8L10 0001
E nd O FCallo ut
Legend
(1) Oil pump
(2) Race
(3) OD planetary gear and OD direct clutch
(4) Race
(5) OD planetary ring gear
(6) Snap ring
(7) Flange, plate and disc (B–0)
(8) Bearing and race
(9) Snap ring
(10) OD support
(11) Race
(12) Snap ring
(13) Second coast brake piston assembly
(14) Direct clutch and forward clutch(15) E-ring and pin
(16) Second coast brake band
(17) Front planetary ring gear
(18) Bearing and race
(19) Race
(20) Snap ring
(21) Front planetary gear
(22) Drum and one-way clutch
(23) Snap ring
(24) Flange, plate and disc (B–2)
(25) Snap ring
(26) Rear planetary gear, second brake drum and
output shaft
(27) Bearing

7A4–18 UNIT REPAIR (AW30–40LE)
5. Remove the overdrive planetary ring gear from the
transmission case.
25 2RY 0 000 2
6. Check piston stroke of overdrive brake
Place a dial indicator onto the overdrive brake
piston as shown in the figure.
25 2RY 0 000 3Measure the stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure.
Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)
If the values are nonstandard, select another flange.Available flange sizes
24 4RY 0 0001
7. Remove the snap ring.
24 6RY 0 0001
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

7A4–20 UNIT REPAIR (AW30–40LE)
Install two removed bolts to the OD support, and
pull out the OD support assembly.
25 2RY 0 000 5
12. Remove the race from OD support.
25 2RY 0 000 6
13. Check piston stroke of second coast brake (B–1)
Place a mark on the second coast brake piston rod
as shown in the figure.
Using feeler gauge, measure the stroke applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band.There are two piston rods.
24 8RY 0 0004
24 8RY 0 0005
Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)

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

7A4–26 UNIT REPAIR (AW30–40LE)
4. Check pack clearance of first and reverse brake.
Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.60 – 1.12 mm (0.0236 – 0.0440 in)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 001 6
5. Install second brake piston sleeve.
24 6RY 0 000 4
6. Install one-way clutch in the transmission case.
24 7RY 0 0011
7. Install discs and plates (B–2).
Instal the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)
24 6RY 0 0005

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

7A4–34 UNIT REPAIR (AW30–40LE)
29. Check piston stroke of overdrive brake.
Place a dial indicator onto the overdrive brake
piston as shown in the figure.
25 2RY 0 000 3Measure the stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure.
Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)
If the values are nonstandard, check for an improper
installation.
Available flange size
24 4RY 0 000 1
Remove the snap ring.
24 6RY 0 0001Remove one flange, four plates and four discs.
24 6RY 0 0026
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

UNIT REPAIR (AW30–40LE) 7A4–43
OD Planetary Gear and OD Direct Clutch Assembly (C–0)
Disassembled View
RTW 37A M F00 0701
E nd O FCallo ut
Legend
(1) OD direct clutch assembly
(2) OD planetary gear assembly
(3) Thrust bearing
(4) Snap ring
(5) Flange, disk and plate
(6) Snap ring
(7) Piston return spring
(8) OD direct clutch piston
(9) O-ring(10) Race and bearing asm
(11) Snap ring
(12) Ring gear flange
(13) OD planetary ring gear
(14) Race
(15) Snap ring
(16) Retaining plate
(17) OD one-way clutch
(18) Thrust washer