ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-7

16ASSY047

11.High clutch hub, bearing, and bearing race

Remove the clutch hub, bearing (with bearing race),
and the bearing race.

Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.

Inspect the bearing race surfaces for damage.



17ASSY040

12.Front sun gear, bearing, and bearing race

Remove the bearing, the front sun gear, and the bearing
race.

Remove the bearing and the bearing race from the fron
t
sun gear.

Inspect the bearing race surfaces for damage.


19ASSY113

13.2-4 brake retainer

Remove the brake seal ring and the sleeve.



23ASSY030



Attach the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0



24ASSY029



Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.

Remove the spring compressor.

7A4-8 UNIT REPAIR (JR405E)

25ASSY019



Remove the 2-4 brake retainer and return spring.



26ASSY026

14.Carrier assembly (Carrier and low clutch assembly),
bearing, bearing race, and 2 – 4 brake assembly

Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.

Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.



27U-SPG02



Remove the 3 brake springs from the transmission case.



28L&R06

15.Low and reverse brake

Remove the snap ring.

Pull the low and reverse brake free.


16.Rear extension (2WD) or Adapter case (4WD)

Rotate the transmission case so that the oil pan opening
is facing up.

Remove the 10 bolts and the rear extension (2WD) o
r
the adapter case (4WD).

UNIT REPAIR (JR405E) 7A4-9

29ASSY091

17.Output shaft

Pull the output shaft from the transmission case.


30ASSY089



Remove the bearing (with bearing race) from the
transmission case.


31ASSY124

18.Parking pawl, shaft, spring, and spacer
Remove the parking pawl, shaft, spring and spacer from the
transmission case.


36ASSY075

19.Actuator support
Remove the actuator support from the transmission case.


37ASSY074

20.Low one-way clutch inner race and bearing

Loosen the 7 bolts securing the low one-way clutch inne
r
race.
NOTE:
Loosen the bolts a little at a time as uniformly as possible
to prevent the inner race from tilting and becoming
jammed.

Remove the 6 bolts. Support the low one-way clutch
inner race with your hand and remove the final bolt.

7A4-10 UNIT REPAIR (JR405E)

39ASSY006



Remove the bearing and the low one-way clutch inner
race from the transmission case.

Remove the bearing from the low one-way clutch inne
r
race.


40ASSY005

21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.


41L&R02

22.Low and reverse brake piston

Force compressed air (329kPa/4.0kg/cm
2) through the
transmission case oil passages.


42ASSY004



Remove the low and reverse brake piston from the
transmission case.

UNIT REPAIR (JR405E) 7A4-11
CONTROL VALVE ASSEMBLY


01CV40

Disassembly steps
1. Oil strainer
Remove the 13 bolts and the oil strainer from the control
valve assembly.


02CV26

2. Harness assembly
Remove the harness assembly.


04CV21

3. Solenoid fixing plate
4. Harness bracket
Remove the 11 bolts and the solenoid fixing plate
together with the harness bracket.


05CV20

7A4-12 UNIT REPAIR (JR405E)

06CV19

5. Solenoid
6. Oil pressure switch Remove the 6 solenoids together and the 3 oil pressure
switchs.


07CV17

7. Control valve upper body
8. Control valve lower body
9. Separation plate
Remove the 17 bolts securing the control valve uppe
r
body, the control valve lower body, and the separation
plate.


08CV16



Separate the upper body, the lower body, and the
separation plate.
NOTE:
Take care not to drop or lose the parts at the inside of the
control valve.

Inspection


Inspect the separation plate for wear and other damage.

UNIT REPAIR (JR405E) 7A4-13

Reassembly steps
Coat the parts with ATF before installing them.

11CV18

1. Control valve upper body
2. Control valve lower body
3. Separation plate
Assembly the control valve upper body, the lower body, and
the separation plate.
Tighten the bolts to the specified torque.



244L300002

7A4-14 UNIT REPAIR (JR405E)

Number Length (Color)
Control valve rocket
bolts and nuts (A) 2 (Plus 2 nuts) 50 mm (1.97 in) (Gold)
Upper body and
lower body fixing
bolts
(B) 2 45 mm (1.77 in) (Silver)
(C) 13 35 mm (1.38 in) (Silver)
Line pressure
solenoid fixing bolt
(D) 1 16 mm (0.63 in) (Gold)

Torque: 8 N




m (69 Ib




in)

UNIT REPAIR (JR405E) 7A4-15
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure
switch connector (wire color: White)
4. Low and reverse brake duty solenoid
connector (wire color: Pink and White)
5. High clutch duty solenoid connector
(wire color: Green and Gray)


6. Lock-up duty solenoid connector (wire
color: Yellow and Black)
7. 2-4 brake duty solenoid connector (wire
color: Blue and Brown)
8. Low clutch duty solenoid connector (wire
color: Orange and Black)
9. Line pressure solenoid connector (wire
color: Pink)

7A4-16 UNIT REPAIR (JR405E)

12CV19

4. Solenoid
5. Oil pressure switch
Install the O-rings to each of the solenoids.

Install the 6 solenoids together and the 3 oil pressure
switchs.
NOTE:
Be sure the high clutch oil pressure switch is marked.

Tighten the bolts to the specified torque.
Torque:
Oil pressure switch bolts – 4.4 N






m (39 Ib






in)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) – 8 N






m (69 Ib






in)
6. Solenoid fixing plate
7. Harness bracket Install the solenoid fixing plate together with the harness
bracket.
Tighten the bolts to the specified torque.

Number Length (Color)
Solenoid fixing plate bolt
(A) 4 16 mm (0.63 in) (Gold)
(B) 7 45 mm (1.77 in) (Silver)

13CV20


Torque: 8 N






m (69 Ib






in)

14CV21



15CV26

8. Harness assembly
Install the harness assembly.