lock ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–9
5. Remove the valve body.
Disconnect the connectors from the solenoid S1
(1), S2 (2), lock-up solenoid (3) and pressure
control solenoid (4).
24 9RY 0 0011
24 9RY 0 001 2
Remove the twenty bolts from valve body.
2 44R20 0078
6. Remove the check valve and spring.
7. Remove two springs from C–0 accumulator piston.
24 0RY 0 0028

7A4–14 UNIT REPAIR (AW30–40LE)
10. Install the solenoid wiring.
Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).
24 9RY 0 0011
24 9RY 0 001 2
11. Install a new oil strainer assembly with gaskets.
24 4RY 0 0002
Install the oil strainer with the gaskets to the valve
body. Tighten the four bolts.
Torque: 10 N·m (87lbin)
24 4RY 0 0003

UNIT REPAIR (AW30–40LE) 7A4–27
8. Install the snap ring.
24 8RY 0 001 4
9. While turning the sun gear input drum clockwise,
install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.
24 8RY 0 002 0
10. Install the front planetary gear and bearing to the
sun gear.
NOTE: Confirm the bearing and race is installed
correctly.
Bearing and race diameter (Reference)
24 7RY 0 0012With wooden blocks under the output shaft, stand
the transmission on the output shaft.
24 7RY 0 0013
Inside Outside
Bearing 35.6 mm (1.40 in) 47.7 mm (1.88 in)
Race 33.7 mm (1.33 in) 47.6 mm (1.87 in)

7A4–44 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of one-way clutch.
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW 37A SH00 450 1
2. Remove OD direct clutch assembly from OD
planetary gear assembly.
2 52L10 000 4
3. Then remove thrust bearing with the race from OD
direct clutch drum.4. Check piston stroke of OD direct clutch (C–0).
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
25 2L10 0005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
25 2L10 0016

7A4–52 UNIT REPAIR (AW30–40LE)
16. Coat the assembled bearing and race with
petroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
2 52L10 001 5
17. Align the flukes of discs in the direct clutch.
Install the OD direct clutch assembly onto the OD
planetary gear.
2 52L10 000 4
18. Check operation of one-way clutch
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW3 7A SH00 4501
E nd OFCa llou t
Inside diameter 28.9 mm (1.138 in)
Outside diameter 50.2 mm (1.976 in)
Legend
(1) Free
(2) Lock

UNIT REPAIR (AW30–40LE) 7A4–65
Disassembly
Remove forward clutch assembly from direct clutch
assembly.
24 8RY 0 003 9
1. Place wooden blocks, etc. to prevent forward clutch
shaft from touching the work stand, and place the
OD support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.
24 8RY 0 004 8
2. Check piston stroke of forward clutch (C–1).
2 48R20 0008Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing compressed
air (390 – 780 kPa or 57 – 114 psi) as shown.
Pack clearance: 0.5 – 0.9 mm (0.020 – 0.035 in)
3. Remove snap ring from clutch drum.
24 8RY 0 0041
4. Remove the flange, disc and plate, and cushion
plate.

7A4–74 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW 37A SH00 460 1
E nd OFCa llou t
2. Remove the one-way clutch and second brake hub.
3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).
24 8RY 0 005 2
5. Remove the snap ring with snap ring pliers.
24 8RY 0 0053
6. Remove the sun gear input drum.
7. Remove the snap ring from planetary sun gear.
Inspection and Repair
1. Check planetary sun gear bushing
Using a dial indicator, measure the inside diameter
of the planetary sun gear bushing.
Maximum inside diameter: 27.08 mm (1.066 in)
If the inside diameter is greater than the maximum,
replace the planetary sun gear.
24 8RY 0 0054
Legend
(1) Free
(2) Lock

UNIT REPAIR (AW30–40LE) 7A4–75
Reassembly
1. Install snap ring to planetary sun gear.
24 8RY 0 005 5
2. Place a wooden block, etc. as a work stand and
place the planetary sun gear onto it.
Install the sun gear input drum onto the planetary
sun gear.
24 8RY 0 005 6
3. Install snap ring with snap ring pliers.
24 8RY 0 0053
4. Coat the two oil seal rings (metal) with ATF.
Install the two oil seal rings onto the planetary sun
gear.
NOTE: Do not spread the ring ends too much.
24 8RY 0 0052

7A4–76 UNIT REPAIR (AW30–40LE)
5. Install thrust washer (plastic).
NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
24 8RY 0 005 7
6. Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
24 8RY 0 005 8
7. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW3 7A SH00 4601
E nd OFCa llou t
Legend
(1) Free
(2) Lock

7A4–82 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove second brake assembly from output shaft.
24 6RY 0 001 4
2. Remove oil seal ring from output shaft.
24 7RY 0 002 8
3. Remove the seven discs, seven plates and flange
(B–3).4. Remove rear planetary gear from rear planetary ring
gear.
24 7RY 0 0029
5. Check operation of No.2 one-way clutch.
Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
RUW3 7A SH00 4701
E nd OFCa llou t
Legend
(1) Lock
(2) Free