reverse ISUZU TF SERIES 2004 Workshop Manual

7A4-32 UNIT REPAIR (JR405E)
CLUTCH PACK (REVERSE AND
HIGH CLUTCH ASSEMBLY)

01R&H17
Legend
1. Reverse and high clutch drum
2. Seal ring (reverse clutch)
3. Lip seal (reverse clutch)
4. Reverse clutch piston
5. Seal ring (small, high clutch)
6. Seal ring (large, high clutch)
7. High clutch piston
8. Return spring
9. High clutch cover
10. Snap ring


11. Dish plate (high clutch)
12. Driven plates (5, high clutch)
13. Drive plates (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plates (2, reverse clutch)
18. Drive plates (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)


02R&H18

Disassembly steps
1. Snap ring
Remove the reverse clutch snap ring.

UNIT REPAIR (JR405E) 7A4-33

03R&H21

2. Retaining plate, drive plate, driven plate and dish plate
Remove the reverse clutch retaining plate, the 2 drive
plates, the 2 driven plates, and the dish plate.


04R&H22

3. Snap ring
Remove the high clutch snap ring.


05R&H25

4. Retaining plate, drive plate, driven plate and dish plate
Remove the high clutch retaining plate, the 5 drive plates,
the 5 driven plates, and the dish plate.


07R&H28

5. Snap ring
6. High clutch cover
7. Return spring
Install the spring compressor to the reverse and high
clutch drum.
Spring compressor: 5-8840-2767-0

Carefully press the high clutch cover down .
Take care not to damage the return spring.

Remove the snap ring.

Remove the high clutch cover and the return spring.

7A4-34 UNIT REPAIR (JR405E)

08R&H36

8. High clutch piston
9. Reverse clutch piston
Install the reverse and high clutch drum to the oil pump.

Force compressed air into the oil pump oil channels.

Remove the high clutch piston and the reverse clutch
piston.


09R&H37



12R&H39

10.Seal ring (high clutch)
Remove the 2 seal rings from the high clutch piston.

13R&H38

11.Seal ring (reverse clutch)
Remove the 2 seal rings from the reverse clutch piston.




Inspection
Drive plate

Measure the drive plate facing thickness at 3 points.

Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)

UNIT REPAIR (JR405E) 7A4-35
Return spring
Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2

Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)


10R&H40

Reverse clutch piston

Apply compressed air (392 kPa/4.0 kg/cm
2) to the
reverse clutch piston from the outside to the inside.
The flow of air should be blocked.


11R&H44



Apply compressed air (392 kPa/4.0 kg/cm2) to the
reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.


12R&H39

Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.

7A4-36 UNIT REPAIR (JR405E)

13R&H38

2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.




RTW47ASH000601
As shown in a figure, oil seal lip is attached.

14R&H32

3. Reverse clutch piston
Install the reverse clutch piston to the reverse and high
clutch drum.


15R&H31

4. High clutch piston
Install the high clutch piston to the reverse clutch piston.


16R&H33

5. Return spring
Install the return spring to the high clutch piston.

UNIT REPAIR (JR405E) 7A4-37

17R&H30

6. High clutch cover

Carefully center the high clutch cover and install it.
NOTE:
If the clutch cover is not centered, the cover outside seal
gum will be forced into the piston area where it will be
damaged.


18R&H27

7. Snap ring

Install the spring compressor to the reverse and high
clutch drum.

Use the spring compressor to carefully force the high
clutch cover down.
Spring compressor: 5-8840-2767-0
NOTE:
To avoid damage to return springs, use only as much
force as is required to press the high clutch cover into
place.

19R&H28



Install the new snap ring to the reverse and high clutch
drum.

20R&H25

8. Dish plate, drive plates, driven plates, and retaining
plate
Install the high clutch dish plate (1), the 5 driven plates (2),
the 5 drive plates (3), and retaining plate (4).






RTW47ASH000501

9. Snap ring
Install the snap ring.

NOTE:
It is careful in the attachment direction of dish plate (1).

7A4-38 UNIT REPAIR (JR405E)

21R&H21

10.Dish plate, drive plates, driven plates, and retaining
plate Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).

248L300003

11.Snap ring
Install the snap ring.

NOTE:
If is careful in the attachment direction of dish plate (1).

22R&H35



Install the reverse and high clutch drum to the oil pump
assembly.

Force compressed air (392 kPa/4.0 kg/cm
2) through the
oil pump oil passages to check high clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


23CLEAR02



Measure the clearance between the high clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)

UNIT REPAIR (JR405E) 7A4-39
248L300004

5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)




24R&H34


Force compressed air (392 kPa/4.0 kg/cm2) through the
oil pump oil passages to check reverse clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.

7A4-40 UNIT REPAIR (JR405E)

25CLEAR04



Measure the clearance between the reverse clutch
retaining plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Reverse clutch retaining plate and snap ring
clearance (B):
0.6~0.9 mm (0.024~0.035 in)
Available reverse clutch retaining plate thicknesses
4.8 mm (0.189 in)
5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)

7A4-48 UNIT REPAIR (JR405E)

25C&L-SUB27

4. Side plate
Install the side plate.


26C&L-SUB26

5. Snap ring
Install the snap ring to the low clutch drum.


27C&L-SUB58



Attach the low one-way clutch inner race to the low
clutch drum in the opposite direction of normal position.

Rotate the one-way clutch inner race clockwise. I
t
should turn smoothly with little resistance.

Rotate the low one-way clutch inner race
counterclockwise.
It should immediately lock (rotation is impossible).
If it does not, check the low one-way clutch installation
direction.
Inspect and replace the low one-way clutch if required.

Remove the low one-way clutch inner race.

Reverse the low clutch drum.


28C&L-SUB32

6. Low clutch piston

Install new seal rings to the low clutch piston.