brake ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-17

Evaluation
i. If there is no engine braking effect in the “2" range:

Second coast (No.1) brake is defective.

ii. If there is no engine braking effect in the “L" range:

First and reverse (No.3) brake is defective.






RUW37ASH000301
iii. Also check to see that downshift is made from 3 2
or from OD to 3 and then to 2 immediately and that
2 
1 downshift point is within the limits shown in the
diagram when tested by releasing the accelerato
r
pedal and shifting into “L" position while driving in
the third gear or in overdrive.



RUW37ASH000401

“ 2" Range Test
Shift into “2" range and, while driving with the
accelerator pedal held constantly at the specified point
(throttle valve opening 50% and 100%), push in one o
f
the pattern selectors (only for 4
4) and check on the
following points.
1.
At each of the above throttle openings, check to see
that the 1 
2 upshift takes place and that the shift
points conform to those shown on the automatic
shift diagram.
NOTE: There is no OD and no lock-up in the “2" range.


RTW46ASH000301

2. While running in the “2" range and 2nd gear,
release the accelerator pedal and check the
engine's braking effect.
3. Check for 2 
1 downshift and abnormal noise at
acceleration and deceleration, and for shock at
upshift and downshift.






RUW37ASH000501

7A3-18 ON-VEHICLE SERVICE (AW30 –40LE)

“ L" Range Test
1. While running above 80 km/h (50 mph) in the “D"
range, release your foot from the accelerator pedal
and shift into the “L" range.
Then check to see that the 2 
1 downshift occurs at
the specified point shown on the automatic shift
diagram.



RUW37ASH000601
2. While running in the “L" range, check to see that
there is no upshift to 2nd gear.
3. While running in the “L" range, release the
accelerator pedal and check the engine braking
effect.
4. Check for abnormal noise during acceleration and deceleration.







RUW37ASH000701

“ R" Range Test
Shift into the “R" range and, while starting at full throttle,
check for slipping.




RUW37ASH000801
“ P" Range Test
Stop the vehicle on a grade (more than 9%) and afte
r
shifting into the “P" range, release the parking brake.
Then check to see that the parking lock pawl holds the
vehicle in place.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-21

Transmission Fluid Level and Condition
Inspection
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from “P" to “L", then return to position “P".
Check to see if the level of fluid comes to “HOT" range
of about 80 
 

C (176 
 

F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in “HOT" range.
Inspection of fluid condition. If the ATF is black o
r
smells burnt, replace it.



RUW37ASH002501

7A3-24 ON-VEHICLE SERVICE (AW30 –40LE)

Brake Signal
Inspection
Check that the brake light comes on when the brake
pedal is depressed.




310RW020

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.

7A3-50 ON-VEHICLE SERVICE (AW30 –40LE)

Major Components
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component
group during assembly, inspect and repair this group
immediately.
General Assembly Notes:
1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful
inspection before assembly because even a small
nick could cause fluid leakage or affect
performance.


2. Before assembling new clutch discs and brake
bands, soak them in automatic transmission fluid fo
r
at least thirty minutes.
3.
Apply automatic transmission fluid on the sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in thei
r
palces.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.



Bearing and Race

RUW36AM F000201

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) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

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