clock ISUZU TF SERIES 2004 Repair Manual

7A4–124 UNIT REPAIR (AW30–40LE)
Torque Converter
Inspection and Repair
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : J–35467
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.
RUW 37A SH00 350 1
1. One-way clutch test.
The clutch should lock when turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5 N·cm (22 Ib in) of torque
should be required to rotate the clutch clockwise. If
necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.

CONSTRUCTION AND FUNCTION 7A1-13

2-4 Brake and Low & Reverse Brake (Multi-Plate Brake)

The multi-plate brake is composed of drive plates and driven plates. By applying the oil pressure onto
the end surface of the plates, the clutch is engaged or disengaged. The oil pressure is adjusted with the
control valve according to the signal from the TCM.

All brakes use dish plates to prevent uncontrolled operation of the clutches when engaged, causing a
shock.

The solenoid in the control valve is driven based on the speed change signal from TCM and moves the
shift valve, thereby engaging the drive plate and driven plate through the piston of each clutch.

Resultantly, rotation of each element of the planetary gear unit is fixed.

When the oil pressure is removed, the piston returns to the original position by the force of the return
spring.




Figure 19. Construction of 2-4 Brake
Figure 20. Construction of Low & Reverse Brake

Low One-way Clutch

The low one-way clutch employs the sprag which locks the counterclockwise rotation of the front planetary
carrier and rear internal gear.

The one-way clutch outer race is fitted with the low clutch drum and the inner race with the transmission
case.

The outer race rotates freely clockwise but, when it attempts to rotate counterclockwise, the sprag
functions to lock the outer race.

When the vehicle is traveling in 1st gear in the D, 3 or 2range, the low one-way clutch locks the rear
internal gear via the low clutch. It is left free in the 2nd, 3rd or 4th gear position.


Figure 21. Construction of Low One-way Clutch

7A1-36 CONSTRUCTION AND FUNCTION
GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION AND
HYDRAULIC CIRCUIT
CONSTRUCTION AND OPERATION
The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate brakes
and one one-way clutch.





COMPONENT NAME AND FUNCTION
Component Name Symbol Function
Low Clutch L/C Connects the front planetary carrier to the rear
internal gear.
Engaged at 1st, 2nd and 3rd gear.
High Clutch H/C Connects the input shaft to the front planetary
carrier.
Engaged at 3rd and 4th (O/D) gear.
Reverse Clutch R/C Connects the input shaft to the front sun gear.
Engaged at Reverse gear.
Low & Reverse Brake L&R/B Locks the front planetary carrier.
Engaged at L range and Reverse gear.
2-4 Brake 2-4/B Locks the front sun gear.
Engaged at 2nd and 4th (O/D) gear.
Low One-way Clutch L/O.C Allows the front planetary carrier to turn forward
(clockwise) but locks to opposite direction
(counterclockwise).
Operative when accelerating.
Low Clutch Solenoid L/C.S Regulates low clutch pressure.
High Clutch Solenoid H/C.S Regulates high clutch pressure.
Low & Reverse Brake Solenoid L&R/B.S Regulates low & reverse brake pressure.
2-4 Brake Solenoid 2-4/B.S Regulates 2-4 brake pressure.
Lock-up Solenoid L/U.S Regulates lock-up clutch pressure.
High Clutch Oil Pressure SW H/C.P/SW Detects high clutch supply oil pressure.
Low & Reverse Brake Oil Pressure SW L&R/B.P/SWDetects low & reverse brake supply oil pressure.
2-4 Brake Oil Pressure SW 2-4/B.P/SWDetects 2-4 brake supply oil pressure.

7A1-40 CONSTRUCTION AND FUNCTION
Reverse Gear in Range
The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. In the R
range, the reverse clutch is engaged and the driving force is transmitted to the front sun gear and rotates it
clockwise. The low & reverse brake is also engaged and the front planetary carrier is fixed so that the front pinion
gear does not rotate clockwise but can rotate counterclockwise. As a result, the output shaft rotates
counterclockwise and the vehicle goes back.

CONSTRUCTION AND FUNCTION 7A1-41
1st Gear in D, 3, 2 Range
The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum.
Since the low clutch is engaged, the movement of the rear internal gear is restricted and, since the low one-
way clutch acts at the same time, counterclockwise rotations of the rear internal gear are locked. As a result,
the driving force transmitted to the rear sun gear rotates the rear planetary carrier clockwise, is decreased in
speed and transmitted to the output shaft.
When decelerating, since the rotating speed of the rear planetary carrier (rear pinion gear) is higher than that
of the rear sun gear and therefore, the rear internal gear attempts to rotate clockwise. At this time, the low
one-way clutch does not act but races and therefore the rear internal gear rotates clockwise. That is, the
reverse torque from the driving shaft is not transmitted to the engine side and therefore, the engine brake
does not act.

CONSTRUCTION AND FUNCTION 7A1-43
2nd Gear in D, 3, 2 Range
The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. As
in the case of the 1st gear, since the low clutch is engaged, the movement of the rear internal gear is
restricted. Since the 2-4 brake is engaged, the front sun gear is fixed. As a result, movement of the rear
internal gear is restricted, and the driving force transmitted to the rear sun gear rotates the rear planetary
carrier clockwise, and is decreased and output. The rotating speed of the rear planetary carrier is increased
as the rear internal gear rotates.
When decelerating, the engine brake is applied.

CONSTRUCTION AND FUNCTION 7A1-45
4th Gear (O/D) in D Range
The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum.
Since the 2-4 brake is engaged, the front sun gear is fixed. As a result, the front pinion gear rotates both
itself and together with other gears clockwise. This rotation increases the speed of rotation of the front
internal gear and is transmitted to the output shaft.

7A3-10 ON-VEHICLE SERVICE (JR405E)
SELECT LEVER
RTW37ALF001101
Legend
1. Rear console
2. Front console
3. Select lever knob
4. Upper housing
5 Lamp assembly

6 Base plate
7 Grooved pin
8 Spring plate
9 Lever assembly
10 Sleeve


Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Remove the rear console and the front console.
4. Remove the 2 screws fixing the select lever knob.
5. Remove the knob together with the knob button and
spring from the lever.
6. Turn the sleeve counterclockwise to remove it. Make
a note of the number of turns required to free the
sleeve.
7. Remove the harness connectors from the base plate.
8. Remove the upper housing (held in place by 4
latched fasteners).
9. Remove the spring plate.

ON-VEHICLE SERVICE (JR405E) 7A3-11
10. Remove the grooved pin.
11. Remove the lever assembly by pressing the rod
down (lever in N position).
12. If lamp replacement is required, remove the lamp
assembly from the lamp socket (align the socke
t
grooved portion and the lamp assembly protruding
portion).

Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.
RTW37ALH000201


1. Install the lever assembly to the base plate.
a. Insert and secure shaft.
b. Insert pawled end of shaft into base plate hole.
c. Insert grooved pin of shaft into detente aperture
(lever assembly in N position).
2.Install the spring plate.
a. Insert the grooved pin into the base plate detente
groove until it touches the front wall (leve
r
assembly in N position).
RTW37ASH001001
b. Stack the short spring plate tighten the screws to
the specified torque.


Screw torque 2 Nm (0.2kgm/17 lb ft)
c. Check that the grooved pin moves smoothly in
the detente groove (shift knob temporarily
installed).
3. Temporarily install the sleeve.
4. Install the lamp assembly to the lamp socket (i
f
removed at disassembly).
a.
Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b. Insert the lamp assembly into the lamp socke
t
and rotate it 90 degrees clockwise.
5. Attach the harness connectors to the base plate.
6. Move the lever to the “P” position.
7. Install the sleeve (rotate the sleeve clockwise the
same number of turns it was rotated
counterclockwise at disassembly).
8. Install the knob, the knob button, and the knob
spring.

7A4-48 UNIT REPAIR (JR405E)

25C&L-SUB27

4. Side plate
Install the side plate.


26C&L-SUB26

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


27C&L-SUB58



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.


28C&L-SUB32

6. Low clutch piston

Install new seal rings to the low clutch piston.