brake ISUZU TF SERIES 2004 Workshop Manual

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

7A4–22 UNIT REPAIR (AW30–40LE)
18. Remove the second coast brake band from the
transmission case.
24 8RY 0 001 0
19. Remove the front planetary ring gear from the
transmission case.
24 7RY 0 000 4
20. Remove the bearing and race.
24 7RY 0 0005
21. Remove the race.
24 7RY 0 0006
22. Using snap ring pliers, remove the snap ring.
24 8RY 0 0011

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

UNIT REPAIR (AW30–40LE) 7A4–25
Reassembly
1. Coat the assembled bearing and race with
petroleum jelly and install it onto the transmission
case.
A ssembled bearing and race (Reference)
24 7RY 0 000 8
2. Install the rear planetary gear, second brake drum
and output shaft.
Align the teeth of the second brake drum,
flanges, discs and plates as shown in the figure.
24 7RY 0 000 9
Align the splines of the transmission case and the
assembled rear planetary gear, second brake
drum and output shaft, indicated by A in the
figure.
24 7RY 0 0010
3. Using snap ring pliers, install the snap ring.
24 6RY 0 0003
Bearing and race Diameter
Inside 39.38 mm (1.550 in)
Outside 58.15 mm (2.289 in)

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

7A4–28 UNIT REPAIR (AW30–40LE)
11. Using snap ring pliers, install the snap ring.
24 8RY 0 0011
12. Coat the bearing race with petroleum jelly and install
it onto the front planetary gear.
Bearing race diameter (Reference)
24 7RY 0 001 4
13. Insert the second coast brake band to the
transmission case.
24 8RY 0 0010
14. Install the E-ring and pin.
Install the pin through the brake band.
24 8RY 0 0021
Bearing race Diameter
Inside 34.3 mm (1.350 in)
Outside 47.8 mm (1.882 in)

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