ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (JR405E) 7A4-27

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter (mm
/ in) Linear
diameter (mm
/ in) Number of
coils
14 Pressure relief 49.0 / 1.929 7.6 / 0.299 1.1 / 0.043 17.3
15 Pressure regulator 30.5 / 1.201 14.0 / 0.551 1.4 / 0.055 5.7
16 Low and reverse brake fail (A) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
17 Fail 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
18 Low and reverse brake amp 19.5 / 0.768 7.9 / 0.311 0.5 / 0.020 6.9
19 2 – 4 brake fail (A) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
20 Low clutch amp (B) 26.0 / 1.024 11.0 / 0.433 0.5 / 0.020 6.9
21
Torque converter relief More than 47.2
/ 1.858 9.2 / 0.362 1.6 / 0.063 20.2
22 2 – 4 brake solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
23 High clutch accumulator 51.0 / 2.008 6.5 / 0.256 0.8 / 0.031 23.5

Oil pressure switch
Apply compressed air (392 kPa/4.0 kg/cm2) to the oil pressure
switch to check the oil pressure switch continuity between the
connector and screw.






244L300011

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between harness
terminals 7 and 6 (ground).

Oil temperature sensor resistance: 2,400




2,600 ohms
(20
 )


Solenoid
Measure the resistance of each solenoid.

Resistance:
Brown connector – 3.0
 3.4 ohms (20
 C)
Gray connector – 12.0
 13.2 ohms (20
 C)
White connector – 12.2
 13.4 ohms (20
 C)

Reassembly steps

Coat the parts with ATF before installing them.

Install the control valve to the control valve lower body.

Install the oil filter to the control valve lower body.

7A4-28 UNIT REPAIR (JR405E)
OIL PUMP ASSEMBLY

01PUMP32
Legend
1. Oil seal
2. O-ring (small)
3. Oil pump housing
4. Inner rotor
5. Outer rotor


6. Oil pump cover
7. O-ring (large)
8. Seal ring (large)
9. Seal ring (small)
10. Bearing race


02PUMP07

Disassembly steps
1. Oil pump cover
2. Oil pump housing
Loosen the 8 bolts evenly a little at a time.

UNIT REPAIR (JR405E) 7A4-29

04PUMP10



Separate the oil pump cover from the oil pump housing
by tapping on each of the bolts with a plastic hammer.



06PUMP13

3. Inner rotor
Remove the inner rotor from the oil pump housing.



07PUMP14

4. Outer rotor
Remove the outer rotor form the oil pump housing.



15PUMP18

5. O-ring (small)
Remove the O-ring (small) from the oil pump housing.



08PUMP09

6. O-ring (large)
Remove the O-ring (large) from the oil pump cover.

7A4-30 UNIT REPAIR (JR405E)

09PUMP05

7. Seal ring
Remove the 4 seal rings from the oil pump cover.



11PUMP43

Inspection
Oil pump cover

Install new seal rings to the oil pump cover.
NOTE:
The seal ring with the large inside diameter fits into the
primary mating surface of the cover.

Measure the gap between the seal ring and the seal ring
groove.
If the measured gap is outside the specified range, the
oil pump cover must be replaced.
Seal ring and seal ring groove gap: 0.10






0.25 mm
(0.0039






0.0098 in)

12PUMP45

Inner rotor

Install the inner rotor to the oil pump housing.

Use a straight edge to measure the side clearance
between the oil pump housing and the inner rotor.
If the measured clearance is outside the specified range,
the inner rotor must be replaced.
Oil pump housing and inner rotor side clearance:
0.02~0.04 mm (0.0008~0.0016 in)

13PUMP46

Outer rotor

Install the outer rotor to the oil pump housing.

Measure the gap between the outer rotor and the
crescent.
If the measured gap is outside the specified range, the
outer rotor must be replaced.
Outer rotor and crescent gap:
0.02~0.15 mm (0.0008~0.0059 in)

UNIT REPAIR (JR405E) 7A4-31


Reassembly steps

15PUMP18

1. O-ring (small)
Install new O-ring (small) to the oil pump housing.

16PUMP29

2. Outer rotor
3. Inner rotor Install the outer rotor and the inner rotor to the oil pump
housing.

17PUMP42

NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.

18PUMP07

4. Oil pump cover
5. Oil pump housing Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
Torque: 9 N 


m (78 Ib 


in)



6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring Install the 4 seal rings to the oil pump cover.

7A4-32 UNIT REPAIR (JR405E)
CLUTCH PACK (REVERSE AND
HIGH CLUTCH ASSEMBLY)

01R&H17
Legend
1. Reverse and high clutch drum
2. Seal ring (reverse clutch)
3. Lip seal (reverse clutch)
4. Reverse clutch piston
5. Seal ring (small, high clutch)
6. Seal ring (large, high clutch)
7. High clutch piston
8. Return spring
9. High clutch cover
10. Snap ring


11. Dish plate (high clutch)
12. Driven plates (5, high clutch)
13. Drive plates (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plates (2, reverse clutch)
18. Drive plates (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)


02R&H18

Disassembly steps
1. Snap ring
Remove the reverse clutch snap ring.

UNIT REPAIR (JR405E) 7A4-33

03R&H21

2. Retaining plate, drive plate, driven plate and dish plate
Remove the reverse clutch retaining plate, the 2 drive
plates, the 2 driven plates, and the dish plate.


04R&H22

3. Snap ring
Remove the high clutch snap ring.


05R&H25

4. Retaining plate, drive plate, driven plate and dish plate
Remove the high clutch retaining plate, the 5 drive plates,
the 5 driven plates, and the dish plate.


07R&H28

5. Snap ring
6. High clutch cover
7. Return spring
Install the spring compressor to the reverse and high
clutch drum.
Spring compressor: 5-8840-2767-0

Carefully press the high clutch cover down .
Take care not to damage the return spring.

Remove the snap ring.

Remove the high clutch cover and the return spring.

7A4-34 UNIT REPAIR (JR405E)

08R&H36

8. High clutch piston
9. Reverse clutch piston
Install the reverse and high clutch drum to the oil pump.

Force compressed air into the oil pump oil channels.

Remove the high clutch piston and the reverse clutch
piston.


09R&H37



12R&H39

10.Seal ring (high clutch)
Remove the 2 seal rings from the high clutch piston.

13R&H38

11.Seal ring (reverse clutch)
Remove the 2 seal rings from the reverse clutch piston.




Inspection
Drive plate

Measure the drive plate facing thickness at 3 points.

Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)

UNIT REPAIR (JR405E) 7A4-35
Return spring
Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2

Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)


10R&H40

Reverse clutch piston

Apply compressed air (392 kPa/4.0 kg/cm
2) to the
reverse clutch piston from the outside to the inside.
The flow of air should be blocked.


11R&H44



Apply compressed air (392 kPa/4.0 kg/cm2) to the
reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.


12R&H39

Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.

7A4-36 UNIT REPAIR (JR405E)

13R&H38

2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.




RTW47ASH000601
As shown in a figure, oil seal lip is attached.

14R&H32

3. Reverse clutch piston
Install the reverse clutch piston to the reverse and high
clutch drum.


15R&H31

4. High clutch piston
Install the high clutch piston to the reverse clutch piston.


16R&H33

5. Return spring
Install the return spring to the high clutch piston.