clutch ISUZU TF SERIES 2004 Workshop Manual

7A4-42 UNIT REPAIR (JR405E)

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Disassembly steps
1. Snap ring
Remove the snap ring from the low clutch drum.


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2. Front carrier
Remove the front carrier from the low clutch assembly.


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3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10.Bearing race Remove the bearing (with bearing race), the rear sun gear,
the bearing, the rear carrier, the bearing race, the bearing,
and rear internal gear.

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7A4-44 UNIT REPAIR (JR405E)

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11.Snap ring
Remove the low clutch snap ring.


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12.Retaining plate, drive plate, driven plate, and dish plate
Remove the low clutch retaining plate, the 7 drive plates,
the 7 driven plates, and the dish plate.

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13.Snap ring

Install the spring compressor to the low clutch drum.
Spring compressor: 5-8840-2759-0

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


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Remove the snap ring.


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14.Cancel cover
Remove the cancel cover.

UNIT REPAIR (JR405E) 7A4-45

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15.Return spring
Remove the return spring.


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16.Low clutch piston

Insert the low one-way clutch inner race to the low clutch
drum.

Force compressed air through the oil passages of the
low one-way clutch inner race to remove the low clutch
piston.


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17.Snap ring

Raise the low one-way clutch side.

Remove the low one-way clutch snap ring.


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18.Side plate
Remove the side plate.

7A4-46 UNIT REPAIR (JR405E)

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19.Low one-way clutch
Remove the low one-way clutch.

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20.Snap ring
Remove the snap ring from the low clutch drum.

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21.Bearing
Remove the bearing.



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)
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): 9.9

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 – 9.7 mm (0.382 in)

UNIT REPAIR (JR405E) 7A4-47
Free length – 36.4 mm (1.433 in)
Linear diameter – 1.2 mm (0.047 in)


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Reassembly steps
Coat the parts with ATF before installing them.
1. Bearing
Install the bearing into the low clutch drum.


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2. Snap ring
Install the snap ring to the low clutch drum.


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3. Low one-way clutch
Install the low one-way clutch to the low clutch drum.


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NOTE:
The flanged side of the low one-way clutch must face the
outside.

7A4-48 UNIT REPAIR (JR405E)

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4. Side plate
Install the side plate.


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5. Snap ring
Install the snap ring to the low clutch drum.


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Attach the low one-way clutch inner race to the low
clutch drum in the opposite direction of normal position.

Rotate the one-way clutch inner race clockwise. I
t
should turn smoothly with little resistance.

Rotate the low one-way clutch inner race
counterclockwise.
It should immediately lock (rotation is impossible).
If it does not, check the low one-way clutch installation
direction.
Inspect and replace the low one-way clutch if required.

Remove the low one-way clutch inner race.

Reverse the low clutch drum.


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6. Low clutch piston

Install new seal rings to the low clutch piston.

UNIT REPAIR (JR405E) 7A4-49

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Install the low clutch piston to the low clutch drum.


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7. Return spring
Install the return spring to the low clutch piston.


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8. Cancel cover

Carefully center the cancel cover and install it.
NOTE:
If the cancel cover is not centered, the cover outside seal
ring gum will be forced into the low clutch piston area
where it will be damaged.

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Install the spring compressor to the low clutch.
Spring compressor: 5-8840-2759-0


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9. Snap ring

Use the spring compressor to carefully force the cancel
cover down.
NOTE:
To avoid damage to the return spring, use only as much
force as is required to press the cancel cover into place.

Install new snap ring to the low clutch drum.

7A4-50 UNIT REPAIR (JR405E)

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10.Dish plate, drive plate, driven plate, and retaining plate
Install the low clutch dish plate (1), the 2 mm thick driven
plate (2), the 7 drive plate (3), the other 6 driven plates (4),
and the retaining plate (5).
NOTE:
Dish plate side with the identification mark must face the
driven plate.

248L300006

11.Snap ring
Install the snap ring to the low clutch drum.

NOTE:
It is careful in the attachment direction of dish plate.

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36CLEAR06


Inspection

Insert the low one-way clutch inner race to the low clutch
drum.

Force compressed air (392 kPa/4.0 kg/cm
2) through the
oil passages of the low one-way clutch inner race to
check low clutch operation.
If the low clutch does not operate, the seal rings may be
damaged or the parts may have been installed in the
wrong order.

Measure the clearance between the low clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing plate with a new plate of the proper size
(thickness).
Low clutch retaining plate and snap ring clearance:
0.9~1.3 mm (0.035~0.051 in)
Available low clutch retaining plate thicknesses
3.8 mm (0.150 in)
4.0 mm (0.157 in)

UNIT REPAIR (JR405E) 7A4-51
248L300007

4.2 mm (0.165 in)
4.4 mm (0.173 in)
4.6 mm (0.181 in)
4.8 mm (0.189 in)

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12.Bearing race
13.Rear internal gear
14.Bearing Install the bearing race and the bearing to the rear internal
gear.
NOTE:
Apply Vaseline to the fitting surfaces of the rear internal
gear to prevent the bearing race and the bearing from
falling during the installation process.


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Install the rear internal gear to the low clutch drum.

7A4-52 UNIT REPAIR (JR405E)

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15.Bearing race
16.Rear carrier
17.Bearing Install the bearing race and the bearing to the rear carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the rear carrier to
prevent the bearing race and the bearing from falling
during the installation process.


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Install the rear carrier to the low clutch drum.


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18.Rear sun gear
Install the rear sun gear to the low clutch drum.


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19.Bearing (with bearing race)
20.Front carrier Install the bearing (with bearing race) to the front carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the front carrier to
prevent the bearing from falling during the installation
process.