ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–43
OD Planetary Gear and OD Direct Clutch Assembly (C–0)
Disassembled View
RTW 37A M F00 0701
E nd O FCallo ut
Legend
(1) OD direct clutch assembly
(2) OD planetary gear assembly
(3) Thrust bearing
(4) Snap ring
(5) Flange, disk and plate
(6) Snap ring
(7) Piston return spring
(8) OD direct clutch piston
(9) O-ring(10) Race and bearing asm
(11) Snap ring
(12) Ring gear flange
(13) OD planetary ring gear
(14) Race
(15) Snap ring
(16) Retaining plate
(17) OD one-way clutch
(18) Thrust washer

7A4–44 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of one-way clutch.
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW 37A SH00 450 1
2. Remove OD direct clutch assembly from OD
planetary gear assembly.
2 52L10 000 4
3. Then remove thrust bearing with the race from OD
direct clutch drum.4. Check piston stroke of OD direct clutch (C–0).
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
25 2L10 0005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
25 2L10 0016

UNIT REPAIR (AW30–40LE) 7A4–45
5. Remove snap ring from clutch drum.
2 52L10 000 6
6. Remove flange, two discs and two plates.
7. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–23327–1
2 52L10 000 7
8. Remove piston return spring
9. Remove the OD direct clutch piston with O-ring.
Place the oil pump onto the torque converter and
then place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand,
apply compressed air to the oil pump to remove
the OD direct clutch piston.Remove the OD direct clutch piston.
25 2L10 0008
10. Remove two O–rings from piston.
11. Remove bearing and race from OD planetary ring
gear.
RTW4 6BSH00 0301

7A4–46 UNIT REPAIR (AW30–40LE)
12. Remove snap ring.
25 2RY 0 002 2
13. Remove ring gear flange from OD planetary ring
gear.
25 2RY 0 002 3
14. Remove the Race.15. Remove snap ring, using screwdriver.
25 2RY 0 0024
16. Remove retaining plate from OD planetary gear.
25 2RY 0 0025
17. Remove OD one-way clutch with outer race.
25 2RY 0 0026

UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 002 7
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
25 2RY 0 002 8
3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
25 2RY 0 0029
4. Check OD direct clutch drum bushings.
Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in)
If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
25 2L10 0009

7A4–48 UNIT REPAIR (AW30–40LE)
5. Check OD planetary gear bushing.
Using a dial indicator, measure the inside diameter
of replace the OD planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.4437 in)
If the inside diameter is greater than the maximum,
replace the OD planetary gear.
25 2RY 0 003 1
Reassembly
1. Install the thrust washer to the OD planetary gear,
facing the grooved side upward.
25 2RY 0 003 2
2. Install the one-way clutch into the outer race, with
the flanged side of the one-way clutch facing
upward.
25 2RY 0 0033
3. Install OD one-way clutch with outer race to
overdrive planetary gear.
25 2RY 0 0026

UNIT REPAIR (AW30–40LE) 7A4–49
4. Install retaining plate, then install snap ring, using a
screwdriver.
25 2RY 0 002 4
5. Coat the race with petroleum jelly and install it to the
planetary gear.
Race diameter (Reference)
25 2RY 0 003 4
6. Install ring gear flange to OD planetary ring gear.
25 2RY 0 0023
7. Install snap ring, using a screwdriver.
25 2RY 0 0022
Inside diameter 24.7 mm (0.972 in)
Outside diameter 41.8 mm (1.646 in)

7A4–50 UNIT REPAIR (AW30–40LE)
8. Install the race and bearing asm onto the OD
planetary ring gear.
Race and bearing asm diameter (Reference)
RTW3 7A SH00 110 1
9. Coat new O-rings with ATF and install them on the
OD direct clutch piston.
10. Being careful not to damage the O-rings, press in
the OD direct clutch piston into the clutch drum,
using both hands.
25 2L10 0011
11. Install piston return spring.
25 2L10 0012
12. Place special tool on the spring retainer, and
compress the return spring.
Spring compressor : J–23327–1
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.
25 2L10 0007
Inside Outside
Bearing
and race24.2 mm (0.953 in) 47.8 mm (1.882 in)

UNIT REPAIR (AW30–40LE) 7A4–51
13. Install two plates and two discs then install the
flange, with the flat side facing downward.
2 52L10 001 3
14. Install snap ring.
2 52L10 001 4
15. Check piston stroke of OD direct clutch (C–0)
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
25 2L10 0005Using a dial indicator, measure the OD direct clutch
piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
25 2L10 0016
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)

7A4–52 UNIT REPAIR (AW30–40LE)
16. Coat the assembled bearing and race with
petroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
2 52L10 001 5
17. Align the flukes of discs in the direct clutch.
Install the OD direct clutch assembly onto the OD
planetary gear.
2 52L10 000 4
18. Check operation of one-way clutch
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW3 7A SH00 4501
E nd OFCa llou t
Inside diameter 28.9 mm (1.138 in)
Outside diameter 50.2 mm (1.976 in)
Legend
(1) Free
(2) Lock