brake ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–77
Second Brake A ssembly (B–2)
Disassembled View
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E nd O FCallo ut
Disassembly
1. Remove second brake assembly from output shaft.
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Legend
(1) Second brake assembly
(2) Thrust washer (Plastic)
(3) Snap ring
(4) Spring retainer(5) Piston return spring
(6) Piston sleeve
(7) Second brake piston
(8) O-ring
(9) Second brake drum

7A4–78 UNIT REPAIR (AW30–40LE)
2. Remove the hrust washer (plastic).
3. Place special tool on the spring retainer, and
compress the return spring.
Spring compressor: J–25048
Remove the snap ring with snap ring pliers.
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4. Remove the spring retainer and piston return spring.
5. Romove piston sleeve.
6. Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
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7. Remove the o-rings from the second brake piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 18.38 mm (0.724 in)
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Reassembly
1. Coat new O-rings with ATF and install them on the
second brake piston.
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2. Being careful not to damage the O-rings, press in
the second brake piston into the second brake
drum.
3. Install piston sleeve.

UNIT REPAIR (AW30–40LE) 7A4–79
4. Install piston return spring.
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5. Install spring retainer.
6. Place special tool on the spring retainer, and
compress the return spring.
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.
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7. Check second brake piston movement.
Make sure the second brake piston moves smoothly
when applying and releasing the low compressed
air to the second brake drum.
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8. Coat the thrust washer (plastic) with petroleum jelly
and install it to the second brake piston, with the
grooved side facing upward.
NOTE: Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
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7A4–80 UNIT REPAIR (AW30–40LE)
9. Install second brake assembly to output shaft.
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UNIT REPAIR (AW30–40LE) 7A4–81
Rear Planetary Gear Assembly and Output Shaft
Disassembled View
2 47R20 0005
E nd O FCallo ut
Legend
(1) Second brake assembly
(2) Output shaft
(3) Oil seal ring
(4) Disc, plate and flange (B–3)
Seven discs and seven plates
(5) Rear planetary gear assembly
(6) One-way clutch inner race
(7) Snap ring(8) One-way clutch
(9) Thrust washer (Plastic)
(10) Thrust washer (Plastic)
(11) Rear planetary gear
(12) Thrust bearing and race
(13) Snap ring
(14) Ring gear flange
(15) Rear planetary ring gear

7A4–82 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove second brake assembly from output shaft.
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2. Remove oil seal ring from output shaft.
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3. Remove the seven discs, seven plates and flange
(B–3).4. Remove rear planetary gear from rear planetary ring
gear.
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5. Check operation of No.2 one-way clutch.
Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
RUW3 7A SH00 4701
E nd OFCa llou t
Legend
(1) Lock
(2) Free

UNIT REPAIR (AW30–40LE) 7A4–85
7. While turning counterclockwise, install one-way
clutch inner race to rear planetary gear.
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8. Check operation of one-way clutch.
Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
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E nd OFCa llou t
9. Install rear planetary gear onto rear planetary ring
gear.
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10. Install the disc, plate and flange (B–3).
Install a brake flange onto the rear planetary gear
assembly.
Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
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Legend
(1) Lock
(2) Free

7A4–86 UNIT REPAIR (AW30–40LE)
Install six clutch discs and six brake plates
alternately, starting with clutch disc, onto the rear
planetary gear assembly.
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11. Coat the oil seal ring with ATF and install it to the
output shaft.
NOTE: Do not spread the ring ends too much.
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12. Install output shaft into rear planetary gear
assembly.
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13. Install second brake assembly to output shaft.
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UNIT REPAIR (AW30–40LE) 7A4–87
First and Reverse Brake (B–3)
Disassembled View
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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.
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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.
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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.
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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.
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