length ISUZU TF SERIES 2004 Repair Manual

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

7A4–54 UNIT REPAIR (AW30–40LE)
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
25 2RY 0 004 3
2. Remove the thrust bearing.
3. Remove the race.
4. Remove the thrust washer (plastic).
5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Remove the snap ring with a screwdriver.
RUW 37A SH00 310 1
6. Romove the piston return spring.7. Place the OD support onto the direct clutch
assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
25 2RY 0 0045
8. Remove the O-ring and oil seal rings from OD
support.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 17.2 mm (0.677 in)
25 2RY 0 0046

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
24 8RY 0 003 0
8. Remove two O-rings from piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)
24 7RY 0 003 4
2. Check discs.
Using 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 0027
3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031

UNIT REPAIR (AW30–40LE) 7A4–67
Before assembling new discs, soak them in ATF
for at least fifteen minutes.
24 8RY 0 004 5
4. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 19.47 mm (0.7665 in)
24 7RY 0 003 4
Reassembly
1. Coat the assembled thrust bearing and race with
petroleum jelly and install it onto the forward clutch
drum, with the race side facing downward.
Bearing and race (Reference)
24 8RY 0 0044
2. Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install
three oil seal rings onto the forward clutch drum.
NOTE: Do not spread the ring ends more than
necessary.
24 8RY 0 0046
Inside diameter 33.7 mm (1.327 in)
Outside diameter 47.8 mm (1.882 in)

7A4–78 UNIT REPAIR (AW30–40LE)
2. Remove the hrust washer (plastic).
3. Place special tool on the spring retainer, and
compress the return spring.
Spring compressor: J–25048
Remove the snap ring with snap ring pliers.
24 7RY 0 000 1
4. Remove the spring retainer and piston return spring.
5. Romove piston sleeve.
6. Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
24 6RY 0 000 8
7. Remove the o-rings from the second brake piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 18.38 mm (0.724 in)
24 7RY 0 0034
Reassembly
1. Coat new O-rings with ATF and install them on the
second brake piston.
24 6RY 0 0009
2. Being careful not to damage the O-rings, press in
the second brake piston into the second brake
drum.
3. Install piston sleeve.

7A4–94 UNIT REPAIR (AW30–40LE)
4. Place upper valve body with plate and gaskets on
top of lower valve body.
Align each bolt hole and gasket in the valve body.
2 44R20 007 4
5. Install the pressure control solenoid and clamp.
6. Install thirty bolts to upper valve body.
Each bolt is indicated in the figure.
Torque: 6.4 N·m (57Ibin)
2 44R20 0050
7. Install manual shift valve.
Length (mm) Quantity
A207
B2812
C4011

UNIT REPAIR (AW30–40LE) 7A4–103
18. Remove the sleeve(31) with the plungers(32)(33),
spring(34) and washer.
Remove the two plungers(32)(33) from the sleeve.
Remove the primary regulator valve(36) from the
valve body(37).
2 44R20 006 0
Inspection and Repair
1. Inspect strainer
Inspect strainer for residual adhesive and damage,
and clean and replace as necessary.
2 44R20 005 1
2. Inspect valve springs
Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than shown below.
mm (in)
2 44R20 0077
SpringFree
lengthColor
(1) By-pass valve21.3
(0.839 )YELLOW
(2) Steel ball20.5
(0.807 )WHITE
(3) 1–2 shift valve 30.8
(1.213 )PURPLE
(4) Low coast modulator valve30.4
(1.197 )LIGHT
GREEN
(5) Accumulator control valve33.8
(1.331)—
(6) Solenoid modulator valve 26.6
(1.047)LIGHT
BLUE
(7) Cut back valve 34.0
(1.339)DARK
BLUE
(8) Primary regulator valve38.58
(1.519)WITHE

UNIT REPAIR (AW30–40LE) 7A4–11 5
16. Remove the retainer (30) for lock-up relay valve with
a magnetic finger by pushing in the sleeve.
2 43R20 007 1
17. Remove the sleeve(31) with the plunger(32),
spring(33) and lock-up relay valve(34).
Remove the lock-up relay valve(34), spring(33) and
plunger(32) from the sleeve(31).
2 43R20 006 5
Inspection and Repair
1. Inspect valve springs
Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than below.
mm (in)
2 43R20 0076
SpringFree
lengthColor
(1) Secondary regulator valve32.9
(1.295)PURPLE
(2) 2–3 shift valve30.8
(1.213)PURPLE
(3) Reverse control valve25.6
(1.008)—
(4) Second coast modulator
valve25.3
(0.996)ORANGE
(5) 3–4 shift valve30.8
(1.213)PURPLE
(6) Lock-up relay valve 23.4
(0.912)RED

7A3-14 ON-VEHICLE SERVICE (JR405E)
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the “N” position.
6. Check that the transmission is in the “N” position.
249R300002
7. Slide the cover in the direction shown by the arrow
(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.
P1010012

9. Connect the shift cable to the manual shaft selec
t
lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.
P1010016-2
11. Press the select lever knob button 5 times.
Then check that the select lever moves smoothly to
each of its positions.
13. Check that the shift position indicated by the selec
t
lever and the actual shift position are the same.
14. Install the front console and rear console.
15. Connect the negative battery cable.
16. Remove the wheel blocks.

ON-VEHICLE SERVICE (JR405E) 7A3-17
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Drain the fluid.
Refer to “ATF CHANGE” in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting
for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign
material, the oil strainer must be replaced.
Further inspection is required to determine the
source of the foreign material.
6. Remove the harness assembly (including oil
temperature sensor).
7. Remove the 11 bolts and the solenoid fixing plate.
8. Remove the 6 solenoids and 3 oil pressure switchs.

Inspect
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.

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




C)
244L300011

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)
Install or connect
1. Install the O-rings to each of the solenoids.
2. Install the 6 solenoids and 3 oil pressure switchs.
Line pressure solenoid bolt torque:
8 N·m (69 lb·in)
Oil pressure switch bolt torque:
4.4 N·m (39 lb·in)
3. Install the solenoid fixing plate together with the
harness brackets.

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

Bolt torque : 8 N·m (69 lb·in)
4. Install the harness assembly.
5. If removed, install the oil strainer.

Number Length (Color)
Oil strainer bolt
(C)
(D)
9
4
13 mm (0.51 in) (Silver)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (69 lb·in)
6. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
7. Fill the fluid.
Refer to “ATF CHANGE” in this section.
8. Connect the negative battery cable.
9. Remove the wheel blocks.