ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–13
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8. Install new check valve and spring.
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9. Install the valve body.
Align the groove of the manual valve to the pin of
the lever.
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Install the twenty bolts.
NOTE: Each bolt length (mm) is indicated in the figure.
Torque: 10 N·m (87lbin)
2 44R20 0078

7A4–14 UNIT REPAIR (AW30–40LE)
10. Install the solenoid wiring.
Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).
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11. Install a new oil strainer assembly with gaskets.
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Install the oil strainer with the gaskets to the valve
body. Tighten the four bolts.
Torque: 10 N·m (87lbin)
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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.
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Install and tighten the nineteen bolts.
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Torque: 7.4 N·m (65lb in)

7A4–16 UNIT REPAIR (AW30–40LE)
Major Components (3)
Major Components (3) and Associated Parts
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E nd O FCallo ut
Legend
(1) Oil pump
(2) Race
(3) OD planetary gear and OD direct clutch
(4) Race
(5) OD planetary ring gear
(6) Snap ring
(7) Flange, plate and disc (B–0)
(8) Bearing and race
(9) Snap ring
(10) OD support
(11) Race
(12) Snap ring
(13) Second coast brake piston assembly
(14) Direct clutch and forward clutch(15) E-ring and pin
(16) Second coast brake band
(17) Front planetary ring gear
(18) Bearing and race
(19) Race
(20) Snap ring
(21) Front planetary gear
(22) Drum and one-way clutch
(23) Snap ring
(24) Flange, plate and disc (B–2)
(25) Snap ring
(26) Rear planetary gear, second brake drum and
output shaft
(27) Bearing

UNIT REPAIR (AW30–40LE) 7A4–17
Disassembly
1. Remove seven bolts fix ing the oil pump to the
transmission case.
Remove the oil pump.
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2. Remove race from oil pump.
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3. Remove the overdrive planetary gear and overdrive
direct clutch with thrust needle bearing from the
transmission case.
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4. Remove the race from OD planetary gear.
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7A4–18 UNIT REPAIR (AW30–40LE)
5. Remove the overdrive planetary ring gear from the
transmission case.
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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
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7. Remove the snap ring.
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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).
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9. Remove the thrust bearing and two races.
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10. Using snap ring pliers, remove the snap ring.
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11. Remove the OD support.
Remove two bolts fix ing the overdrive support
assembly to the transmission case.
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7A4–20 UNIT REPAIR (AW30–40LE)
Install two removed bolts to the OD support, and
pull out the OD support assembly.
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12. Remove the race from OD support.
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13. Check piston stroke of second coast brake (B–1)
Place a mark on the second coast brake piston rod
as shown in the figure.
Using feeler gauge, measure the stroke applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band.There are two piston rods.
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24 8RY 0 0005
Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)

UNIT REPAIR (AW30–40LE) 7A4–21
14. Using snap ring pliers, remove the snap ring.
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15. Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
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16. Remove the direct clutch and forward clutch from
the transmission case.
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17. Remove the E-ring from the pin.
Remove the pin from the brake band.
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7A4–22 UNIT REPAIR (AW30–40LE)
18. Remove the second coast brake band from the
transmission case.
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19. Remove the front planetary ring gear from the
transmission case.
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20. Remove the bearing and race.
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21. Remove the race.
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22. Using snap ring pliers, remove the snap ring.
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