brake ISUZU TF SERIES 2004 Workshop Manual

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) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

UNIT REPAIR (AW30–40LE) 7A4–53
OD Support Assembly
Disassembled View
2 52R20 0003
E nd O FCallo ut
Disassembly
1. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.
25 2RY 0 0042
Legend
(1) Thrust bearing
(2) Race
(3) Thrust washer (plastic)
(4) Snap ring(5) Piston return spring
(6) OD brake piston
(7) O-ring
(8) Oil seal ring
(9) OD support

7A4–54 UNIT REPAIR (AW30–40LE)
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
25 2RY 0 004 3
2. Remove the thrust bearing.
3. Remove the race.
4. Remove the thrust washer (plastic).
5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Remove the snap ring with a screwdriver.
RUW 37A SH00 310 1
6. Romove the piston return spring.7. Place the OD support onto the direct clutch
assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
25 2RY 0 0045
8. Remove the O-ring and oil seal rings from OD
support.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 17.2 mm (0.677 in)
25 2RY 0 0046

UNIT REPAIR (AW30–40LE) 7A4–55
Reassembly
1. Coat the two oil seal rings with ATF.
Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.
25 2RY 0 004 7
2. Coat two new O-rings with ATF and install them on
the OD brake piston.
3. Being careful not to damage the O-rings, press the
brake piston into the OD support, using both hands.
25 2RY 0 004 8
4. Install piston return spring.
25 2RY 0 0049
5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
with cutout portion of the OD support.
RUW3 7A SH00 3201

7A4–56 UNIT REPAIR (AW30–40LE)
6. Coat the thrust washer (plastic) with petroleum jelly
and install it onto the OD support.
NOTE: Make sure that the lug fits into the hole on the
OD support.
25 2RY 0 005 1
7. Coat the race with petroleum jelly, and install it onto
the OD support.
Race diameter (Reference)
25 2RY 0 005 2
8. Turn over OD support.
Coat the two races with petroleum jelly, and install
them onto the OD support.
Race and bearing diameter (Reference)
25 2RY 0 0069
9. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.
25 2RY 0 0042
Inside diameter 36.7 mm (1.44 in)
Outside diameter 50.85 mm (2.00 in)
Inside Outside
Race (A) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
Bearing and
race (B)33.7 mm (1.327 in) 50.1 mm (1.972 in)

UNIT REPAIR (AW30–40LE) 7A4–57
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
25 2RY 0 004 3

UNIT REPAIR (AW30–40LE) 7A4–73
Planetary Sun Gear and No.1 One-Way Clutch
Disassembled View
2 48R20 0005
E nd O FCallo ut
Legend
(1) One-way clutch and second brake hub
(2) Thrust washer (plastic)
(3) Oil seal ring (Metal)(4) Snap ring
(5) Sun gear input drum
(6) Snap ring
(7) Planetary sun gear

7A4–74 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW 37A SH00 460 1
E nd OFCa llou t
2. Remove the one-way clutch and second brake hub.
3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).
24 8RY 0 005 2
5. Remove the snap ring with snap ring pliers.
24 8RY 0 0053
6. Remove the sun gear input drum.
7. Remove the snap ring from planetary sun gear.
Inspection and Repair
1. Check planetary sun gear bushing
Using a dial indicator, measure the inside diameter
of the planetary sun gear bushing.
Maximum inside diameter: 27.08 mm (1.066 in)
If the inside diameter is greater than the maximum,
replace the planetary sun gear.
24 8RY 0 0054
Legend
(1) Free
(2) Lock

7A4–76 UNIT REPAIR (AW30–40LE)
5. Install thrust washer (plastic).
NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
24 8RY 0 005 7
6. Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
24 8RY 0 005 8
7. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW3 7A SH00 4601
E nd OFCa llou t
Legend
(1) Free
(2) Lock