reverse ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-39

Installation
To install, follow the removal steps in reverse order
noting the following point;
1. Reinstall the parts removed with the valve bod
y
assembly to their assigned positions in the
transmission case (check valve assembly, C0
accumulator pistons, etc). Install the valve bod
y
assembly to the transmission case.
Refer to REASSEMBLY OF MAJO
R
COMPONENTS (2).
2. Solenoid clamp bolt
Torque : 7 N 


m (61 Ib in)
3. Valve body fixing bolts
Each bolt location and length (mm) is indicated in
the figure.
Torque : 10 N 


m (87 Ib in)
NOTE: Tighten the bolts toward outside equally.




244R200078
4. Oil strainer fixing bolts
Torque : 10 N 


m (87 Ib in)
5. Oil pan fixing bolts
Torque : 8 N 


m (69 Ib in)

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

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

7A4–24 UNIT REPAIR (AW30–40LE)
27. Check pack clearance of first and reverse brake (B–
3)
Using a feeler gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.6 – 1.12 mm (0.0236 – 0.0440 in)
If the values are nonstandard, replace the discs.
24 8RY 0 001 6
28. Using snap ring pliers, remove the snap ring.
24 8RY 0 001 7
29. Remove the rear planetary gear, second brake drum
and output shaft as an assembly.
2 47R20 0001
30. Remove the assembled thrust bearing and race
from the transmission case.
24 8RY 0 0018

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) 7A4–87
First and Reverse Brake (B–3)
Disassembled View
24 6RY 0 0024
E nd O FCallo ut
Legend
(1) Thrust bearing and race
(2) Snap ring
(3) Piston return spring
(4) First and reverse brake piston No.2(5) O-ring
(6) Reaction sleeve
(7) O-ring
(8) First and reverse brake piston No.1
(9) O-ring

7A4–88 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove assembled thrust bearing and race from
transmission case.
24 7RY 0 004 3
2. Check first and reverse brake piston movement.
Make sure that first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
24 6RY 0 001 6
3. Set special tool on the spring retainer, and
compress the return spring.
Spring compressor: J–25048
Remove the snap ring with snap ring pliers.
24 7RY 0 0002
4. Remove the piston return spring.
5. Remove the first and reverse brake piston No.2.
Holding the first and reverse brake piston No.2 by
hand, apply compressed air to the transmission
case to remove the first and reverse brake piston
No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air,
lift the piston out with needle-nose pliers.
24 6RY 0 0016

UNIT REPAIR (AW30–40LE) 7A4–89
6. Remove the O-ring from first and reverse brake
piston No.2.
7. Remove the reaction sleeve.
Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: J–37236
RUW 37A SH00 330 1
8. Remove the O-ring from reaction sleeve.
9. Remove the first and reverse brake piston No.1.
Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the
transmission case.
Piston puller: J–37237
RUW 37A SH00 340 1
10. Remove the O-rings from first and reverse brake
pistion No.1.
Reassembly
1. Coat three new O-rings with ATF.
Install the two O-rings on the No.1 piston.
2. Install the O-ring on the reaction sleeve.
3. Install the first and reverse brake piston No.1 to the
reaction sleeve.
24 6RY 0 0018
4. Coat a new O-ring with ATF and install it on the first
and reverse brake piston No.2.
5. Install the first and reverse brake piston No.1 with
reaction sleeve onto the first and reverse brake
piston No.2.
24 6RY 0 0019

7A4–90 UNIT REPAIR (AW30–40LE)
6. Align the teeth of the first and reverse brake piston
No.2 into the proper grooves.
Being careful not to damage the O-rings, press in
the first and reverse brake piston No.2 with No.1
into the transmission case.
24 6RY 0 002 0
7. Place piston return spring onto first and reverse
brake piston No.2.
24 6RY 0 002 1
8. Set special tool as shown, and compress the return
spring with special tool.
Spring compressor: J–25048
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
24 7RY 0 0002
9. Check first and reverse brake piston movement.
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
24 6RY 0 0022

7A4–110 UNIT REPAIR (AW30–40LE)
Disassembled View
2 43R20 0074
E nd O FCallo ut
Legend
(1) Check ball
(2) Retainer
(3) Check valve NO.2
(4) Ball
(5) Check valve NO.1
(6) Retainer
(7) Check valve NO.2
(8) Ball
(9) Check valve NO.1
(10) Retainer
(11) Plug
(12) Secondary regulator valve
(13) Spring
(14) Retainer
(15) Plug
(16) Spring
(17) 2–3 shift valve(18) Retainer
(19) Plug
(20) Spring
(21) Reverse control valve
(22) Retainer
(23) Plug
(24) Second coast modulator valve
(25) Spring
(26) Retainer
(27) Plug
(28) 3–4 shift valve
(29) Spring
(30) Retainer
(31) Sleeve
(32) Plunger
(33) Spring
(34) Lock-up relay valve
(35) Upper valve body