Transmission ISUZU TF SERIES 2004 Workshop Manual

7A4–6 UNIT REPAIR (AW30–40LE)
6. Install the elbow.
Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29 N·m (3.0kg·m/22 Ib ft)
RTW 37BSH00 060 1
7. Install the select lever.
8. Install the output revolution sensor (4
2).
9. Install the output revolution sensor (4
4).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter.
Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5 mm (0.53 in)
24 0RY 0 000 5

7A4–8 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove the six bolts and remove the converter
housing.
2 40R20 002 2
2. Remove the oil pan.
NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove the nineteen bolts.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J–37228
RUW 37A SH00 290 1
3. Ex amine particles in oil pan.
Remove the magnet and use it to collect any
steel chips. Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear
24 0RY 0 0008
4. Remove the oil strainer assembly.
Remove four bolts holding the oil strainer.
24 4RY 0 0003

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

UNIT REPAIR (AW30–40LE) 7A4–15
12. Install the oil pan.
Install two magnets in oil pan.
Remove any gasket material and be careful not to
drop oil on the contacting surfaces of the
transmission case and oil pan.
Apply liquid gasket (TB1281 or its equivalent) to the
oil pan as shown in the figure.
NOTE: Install the oil pan as soon as the seal gasket is
applied.
24 0RY 0 001 9
Install and tighten the nineteen bolts.
24 0RY 0 002 0
Torque: 7.4 N·m (65lb in)

UNIT REPAIR (AW30–40LE) 7A4–17
Disassembly
1. Remove seven bolts fix ing the oil pump to the
transmission case.
Remove the oil pump.
24 1RY 0 000 3
2. Remove race from oil pump.
24 1RY 0 000 2
3. Remove the overdrive planetary gear and overdrive
direct clutch with thrust needle bearing from the
transmission case.
25 2L10 0001
4. Remove the race from OD planetary gear.
25 2L10 0017

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)

UNIT REPAIR (AW30–40LE) 7A4–19
8. Remove one flange, four plates and four discs (B–
0).
24 6RY 0 002 6
9. Remove the thrust bearing and two races.
24 7RY 0 000 3
10. Using snap ring pliers, remove the snap ring.
24 6RY 0 0002
11. Remove the OD support.
Remove two bolts fix ing the overdrive support
assembly to the transmission case.
25 2RY 0 0004

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