Transmission ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-45

19.Support the transmission with a transmission jack.



220RS0001
20.Remove the transmission crossmember.

Remove engine rear mount nuts fixing on
transmission crossmember.





P1010018

Remove the transmission crossmember by
removing four fixing bolts.
 If necessary, remove the rear mount rubber from
the transmission.
21. Disconnect the air bleezer hose at the transmission.

22.Remove the protector and fuel pipe bracket.

Loosen the nut (1) and remove the protector (2).
 Remove the bracket with the fuel pipes (3) and
put aside it.



RTW37ASH001201
23.Remove the transmission assembly.

Remove transmission retaining nuts and bolts.
 Remove transmission assembly from the vehicle.

7A3-46 ON-VEHICLE SERVICE (AW30 –40LE)

Installation
1. Install the rear mounting rubber on the
transmission.
Torque: 50 N m (5.1 kg m/36 lb ft)
2. Attach the transmission to the engine.

Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine.

Attach the transmission to the engine.
 Tighten engine transmission bolts as shown in
the figure.






RTW37ALF000301

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-47

3. Install the protector and fuel pipe bracket.

Install the bracket with the fuel pipes (3) to the
transmission.
 Install the protector (2) and tighten nuts (1).



RTW37ASH001201
4. Connect the air bleezer hose on the transmission.
5. Install the transmission crossmember.
Torque: 67 N 


m (6.8 kg 


m/49 lb ft)
6. Install the heat protector and the fuel pipe clips with
fuel pipes on the transmission crossmember.





P1010005B
7. Install rear mount nuts.
Torque: 50 N 


m (5.3 kg



m/37 lb ft)
8. Remove a transmission jack.

9. Install flex plate torque converter bolts.

Align the flex plate torque converter bolt boss
with flex plate hole by turning the torque
converter.
 Install flex plate torque converter bolts (6 pieces)
by turning the crankshaft.
Torque: 54 N 


m (54 kg



m/40 lb ft)
NOTE: Do not reuse the flex plate torque converte
r
bolt.





P1010005
10.Install the under covers to the transmission and
engine.
Torque: 8 N 


m (0.8 kg



m/69 lb in)





P1010012

7A3-48 ON-VEHICLE SERVICE (AW30 –40LE)

11. Install the suspension crossmember.
Torque: 65 N 


m (6.6 kg 


m/48 lb ft)
12. Install filler tube and insert oil level gage.
Torque: 22 N 


m (2.2 kg 


m/16 lb ft)
13. Install select cable by connecting inner cable to
select lever and installing outer cable with bracket.
14. Install the fuel pipe brackets to the transmission. Install the fuel pipe clips with the pipes to the
bracket.





P1010010
15. Connect the transmission harness connectors and
clips.
16. Connect transmission oil cooler pipes to A/T.
Torque: 44 N 


m (4.5 kg



m/33 lb ft)
17. Install oil cooler pipe clamp and bracket to the
converter housing.


18.Tighten oil cooler pipe clamp bolt at the engine
mount side.




P1010024
19. Install the transfer case assembly.(4WD only)

Apply a thin coat of molybdenum disulfide grease
to the input shaft spline as shown in the figure.


260R300001

Install the transfer case assembly.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-49


Tighten transmission transfer bolts as shown in
the figure.(4WD only)

261R300002
20. Connect transfer harness connectors and
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
21. Install the middle exhaust pipe.



RTW37ASH0001
22. Install the rear propeller shaft.
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.
23. Install the center bearing on crossmember.
Torque: 69 N 


m (7.0 kg 


m/51 lb ft)


24.Install the front propeller shaft.(4WD only)
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.


401RS023
25. Connect battery ground cable.

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) 7A4–3
Major Components (1)
Major Components (1) and Associated parts
RTW 37A M F00 0601
E nd O FCallo ut
Disassembly steps
1. Remove the torque converter.
2. Remov e the select lev er.
Legend
(1) Torque converter
(2) Select lever
(3) Neutral start switch (Mode switch)
(4) Elbow
(5) Oil temperature sensor
(6) Breather hose
(7) Input revolution sensor(8) Output revolution sensor (4
4)
(9) Output revolution sensor (4
2)
(10) Speedometer sensor, speedometer driven gear
and plate (4
2)
(11) Extension housing (4
2)
(12) Adapter housing (4
4)
(13) Transmission assembly

7A4–4 UNIT REPAIR (AW30–40LE)
3. Remove the neutral start switch (Mode switch).
Unstake the lock washer.
Remove the nut and bolt, and then remove the
neutral start switch.
Remove the lock washer.
RTW 37BSH00 010 1
4. Remove the two elbows from transmission case.
24 0RY 0 000 1
5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4
4).
9. Remove the output revolution sensor (4
2).
10. Remove the speedometer sensor, speedometer
driven gear and plate (4
2).
11. Remove the ex tension housing (4
2).
12. Remove the adapter housing (4
4).13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fix ture: J–37227
Holding fix ture base: J–3289–20
RUW3 7A SH00 3001

UNIT REPAIR (AW30–40LE) 7A4–5
Components (1)
Reassembly
1. Install a new gasket and the ex tension housing
(4
2) to the transmission case.
Torque: 36 N·m (27 Ib ft)
2. Install the speedometer driven gear, plate, and
speedometer sensor (4
2).
To r q u e :
Plate bolt – 15 N·m (11 Ib ft)
Speedometer sensor – 25 N·m (18 Ib ft)
3. Install the adapter housing (4
4).
Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
24 1RY 0 002 0
Apply liquid gasket (TB1281–B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
Install the adapter housing to the transmission
case.
Torque: 34 N·m (25 Ib ft)
4. Install the neutral start switch.
Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
Install the lock washer and nut.
Torque: 7 N·m (61 Ib in)Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (113 Ib in)
Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW1 7A SH01 3601
5. Install the oil temperature sensor to the transmission
case.
Torque: 15 N·m (11 Ib ft)
RUW3 7A SH00 4001