transmission ISUZU TF SERIES 2004 Workshop Manual

7A4-72 UNIT REPAIR (JR405E)

03ASSY013

3. Carrier and low clutch assembly
Install the carrier and low clutch assembly to the
transmission case.
NOTE:
Do not allow the low clutch drum end to protrude beyond
the 2-4 brake plate contact surface (transmission case).


04ASSY014

4. Bearing
Install the bearing to the carrier and low clutch assembly.


05ASSY015

5. Driven plate, drive plate, retaining plate, and dish plate
(2 – 4 brake)
Install the 2-4 brake 5 driven plate (1), 5 drive plates (2),
retaining plate (3), and dish plate (4) in that order.
NOTE:







The thickest driven plate (5.6 mm) must be installed
at the bottom (transmission case plate surface).







Dish plate side with the identification mark must
face the retaining plate.


06ASSY016



07ASSY017

UNIT REPAIR (JR405E) 7A4-73

08ASSY018






RTW47ASH000401



09U-SPG2

6. 2
– 4 brake spring
Install the 2-4 brake springs (3) to the transmission case.





248L300009

7A4-74 UNIT REPAIR (JR405E)

10ASSY019

7. Return spring and 2
– 4 brake retainer

Align the transmission case groove and the 2-4 brake
retainer projection.

Install the return spring and the 2-4 brake retainer.

11ASSY028



12ASSY029

Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Carefully center the spring compressor to prevent damage
to the return spring.

Push the 2-4 brake retainer into place.
NOTE:
Do not push the brake retainer too far.
Damage to the return spring will result.

Install the snap ring.


14ASSY031



17ASSY113

8. Sleeve and seal ring

Install the new sleeve and seal ring to the transmission
case.

UNIT REPAIR (JR405E) 7A4-75

192-4B22



Force compressed air (392 kPa/4.0 kg/cm2) through the
transmission case oil passage to 2-4 brake operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing

Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040

Install the front sun gear to the transmission case.


22ASSY042

Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.

7A4-76 UNIT REPAIR (JR405E)

24ASSY047



Install the high clutch hub and the bearing race to the
transmission case.


25R&H42

11.Clutch pack (reverse and high clutch assembly)

Install the bearing (with bearing race) to the clutch pack.
NOTE:







The black side (bearing race) of the bearing must
contact the clutch pack.







Apply Vaseline to the bearing.


26ASSY049



Install the clutch pack and bearing to the transmission
case.



27ASSY051



Install the bearing to the clutch pack.
NOTE:
Apply Vaseline to the bearing.







RTW47ASH000101

Total end play measurement

Install the bearing race (oil pump) to the clutch pack.

Measure the distance (A) between the oil pump
installation surface and the bearing race.

7A4-78 UNIT REPAIR (JR405E)

30ASSY067



Apply ATF to the O-ring at the outside of the oil pump.

Install the oil pump assembly to the transmission case.


Apply sealing agent (TB1215) to the threaded surfaces
of the 8 fixing bolts and tighten to the specified torque.
Torque: 58 N 


m (43 Ib 


ft)


31ASSY068

14.O-ring
Install a new O-ring to the input shaft.


32ASSY116

15.Converter housing
Install the converter housing and tighten the bolts to the
specified torque. Torque: 53 N 


m (39 Ib 


ft)


33ASSY075

16.Actuator support
Install the actuator support.


34ASSY077

17.Parking pawl, shaft, spring, and spacer
Install the parking pawl, the shaft, the spring, and the
spacer.

7A4-80 UNIT REPAIR (JR405E)

40ASSY091



Push the output shaft into place.


19.Rear extension (2WD) or adapter case (4WD)

Use the oil seal installer to install the oil seal to the rea
r
extension (2WD) or adapter case (4WD).
Oil seal installer:
5-8840-2769-0 (2WD)
5-8840-2770-0 (4WD)

41ASSY096



Install the bearing (with bearing race) to the rear
extension (2WD) or adapter case (4WD).
NOTE:







The black side (bearing race) of the bearing must be
visible.







Apply Vaseline to the bearing.




249L300005



Apply sealing agent (TB1216B) to the rear extension
(2WD) or adapter case (4WD) contact surfaces.



249L300006

Install the rear extension (2WD) or adapter case (4WD)
to the transmission case and tighten the 10 bolts to the
specified torque.
Torque: 53 N 


m (39 Ib 


ft)

UNIT REPAIR (JR405E) 7A4-81

43ASSY119

20.Control valve assembly


Align the manual valve and the manual plate of the
transmission case.











Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

44ASSY121


Torque: 8 N 


m (69 Ib 


in)



45CV29



Connect the harness assembly and control valve
assembly connectors.

7A4-82 UNIT REPAIR (JR405E)
244L300001


21.Oil pan

Install a new gasket and the oil pan.

Tighten the bolts to the specified torque.
Torque: 8 N 


m (69 Ib 


in)

47INH-SW01

22.Inhibitor switch

Secure the inhibitor switch (1) by hand-tightening the 2
bolts.

Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.

Tighten the 2 inhibitor switch bolts to the specified
torque.

UNIT REPAIR (JR405E) 7A4-83
Torque: 5.5 N
 m (48 Ib
 in)

Remove the holding fixture from the transmission case.



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23.Speed sensor and turbine sensor

Apply ATF to the new O-rings and install them the speed
sensor (2) and the turbine sensor (3).

Install the speed sensor and the turbine sensor. Tighten
the bolt to the specified torque.
Torque: 6 N
 m (52 Ib
 in)
24.Torque converter

Pour the new ATF into the torque converter.

Shake the torque converter to thoroughly clean the
inside.

Drain the ATF from the torque converter.

Pour the new ATF into the torque converter.
NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.


RTW47ASH000901


Install the torque converter.

Measure the torque converter end play (A).
If the measured value is greater than the specified
minimum, the torque converter is correctly installed.
Torque converter end pay (Minimum): 67 mm (2.64
in)