ISUZU TF SERIES 2004 Workshop Manual

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.
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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

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

UNIT REPAIR (AW30–40LE) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

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.
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UNIT REPAIR (AW30–40LE) 7A4–9
5. Remove the valve body.
Disconnect the connectors from the solenoid S1
(1), S2 (2), lock-up solenoid (3) and pressure
control solenoid (4).
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Remove the twenty bolts from valve body.
2 44R20 0078
6. Remove the check valve and spring.
7. Remove two springs from C–0 accumulator piston.
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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.
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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.

UNIT REPAIR (AW30–40LE) 7A4–11
16. Remove the spacer, rotor, key and snap ring (4
2).
Remove the spacer, rotor and key.
Remove the snap ring from the output shaft.
2 47L10 000 1
Reassembly
1. Install the converter housing.
To r q u e :
M10 – 34 N·m (25 lb ft)
M12 – 57 N·m (42 lb ft)
2 40R20 002 2
2. Install the snap ring, key and rotor (4
2).
Install the snap ring to the output shaft.
Install the key and rotor.3. Install the spacer, ball, speedometer sensor drive
gear and snap ring (4
2).
Install the spacer, ball and speedometer sensor
drive gear.
Install the snap ring to the output shaft.
24 7L10 0001
4. Install the key, rotor and snap ring (4
4).
Install the key and rotor.
Install the snap ring to the output shaft.
2 47R20 0002

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