lock ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–85
7. While turning counterclockwise, install one-way
clutch inner race to rear planetary gear.
24 7RY 0 004 0
8. Check operation of 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.
RUW 37A SH00 470 1
E nd OFCa llou t
9. Install rear planetary gear onto rear planetary ring
gear.
24 7RY 0 0029
10. Install the disc, plate and flange (B–3).
Install a brake flange onto the rear planetary gear
assembly.
Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
24 6RY 0 0013
Legend
(1) Lock
(2) Free

UNIT REPAIR (AW30–40LE) 7A4–97
Disassembled View
2 44R20 0075
Legend
(1) By-pass valve
(2) Spring
(3) Strainer
(4) Shift solenoid S1
(5) Shift solenoid S2
(6) Lock-up solenoid SL
(7) Clamp
(8) Accumulator sub-assembly
(9) Retainer
(10) Spring
(11) Ball
(12) Retainer
(13) Plug
(14) Spring
(15) 1–2 shift valve
(16) Retainer
(17) Spring(18) Low coast modulator valve
(19) Retainer
(20) Plug
(21) Spring
(22) Accumulator control valve
(23) Retainer
(24) Spring
(25) Solenoid modulator valve
(26) Retainer
(27) Plug
(28) Spring
(29) Cut back valve
(30) Retainer
(31) Sleeve
(32) Plunger
(33) Plunger
(34) Spring
(35) Washer
(36) Primary regulator valve

7A4–98 UNIT REPAIR (AW30–40LE)
E nd O FCallo ut
Disassembly
1. Remove by-pass valve and spring.
2 44R20 006 3
2. Remove three strainers.
2 44R20 006 4
NOTE: Confirm six retainers are installed correctly.
2 44R20 0066
3. Remove the shift solenoid S1 and shift solenoid S2.
Remove the fix ing bolt.
Remove the shift solenoid S1 (2) and S2 (1) from
each bore.
Remove the O-rings from each solenoid.
4. Remove the lock-up solenoid SL
Remove the fix ing bolt.
Remove the lock-up solenoid SL (3) from the
bore.
Remove the O-ring from solenoid.
5. Remove the accumulator sub-assembly
Remove the clamp.
Remove the accumulator sub-assembly (4) from
the bore. (37) Lower valve body

UNIT REPAIR (AW30–40LE) 7A4–107
12. Install the retainer(12) by pushing the plug.
2 44R20 006 7
13. Install the ball(11), spring(10) and retainer (9) to the
valve body.
Torque: 6.9 N·m (60Ibin)
2 44R20 005 2
14. Install the accumulator sub-assembly (8) and
clamp(7) to the valve body.
Torque: 10 N·m (87Ibin)
15. Install a new O-ring to the lock-up solenoid SL (6).
Install the solenoid to the valve body.
Torque: 10 N·m (87Ibin)16. Install a new O-ring to the shift solenoid S2 (5) and
shift solenoid S1 (4).
Install the solenoids to the valve body.
Torque: 10 N·m (87Ibin)
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NOTE: Make sure six retainers are installed correctly.
2 44R20 0066
Legend
(4) Shift Solenoid S1
(5) Shift Solenoid S2
(6) Lock-up Solenoid SL
(8) Accumulator Sub-assembly
(9) Retainer

7A4–110 UNIT REPAIR (AW30–40LE)
Disassembled View
2 43R20 0074
E nd O FCallo ut
Legend
(1) Check ball
(2) Retainer
(3) Check valve NO.2
(4) Ball
(5) Check valve NO.1
(6) Retainer
(7) Check valve NO.2
(8) Ball
(9) Check valve NO.1
(10) Retainer
(11) Plug
(12) Secondary regulator valve
(13) Spring
(14) Retainer
(15) Plug
(16) Spring
(17) 2–3 shift valve(18) Retainer
(19) Plug
(20) Spring
(21) Reverse control valve
(22) Retainer
(23) Plug
(24) Second coast modulator valve
(25) Spring
(26) Retainer
(27) Plug
(28) 3–4 shift valve
(29) Spring
(30) Retainer
(31) Sleeve
(32) Plunger
(33) Spring
(34) Lock-up relay valve
(35) Upper valve body

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

7A4–116 UNIT REPAIR (AW30–40LE)
Reassembly
1. Install the plunger(32) and spring(33) into the
sleeve(31).
Install the lock-up relay valve(34) into the
sleeve(31).
Install the sleeve(31) with the plunger(32),
spring(33) and lock-up relay valve(34) into the bore.
2 43R20 006 5
2. Install the retainer(30).
2 43R20 007 1
3. Install the spring, 3-4 shift valve(28) and plug(27)
into the bore.
2 43R20 0064
4. Install the retainer(26) by pushing the plug.
2 43R20 0072

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.

7A4–128 UNIT REPAIR (AW30–40LE)
Main Data and Specifications
General Specifications
Remaks
Model AW30–40LE
Engine 6VE1 (3.5L)
Type Electronic control planetary gear type
3–element 1–stage 2–phase type
(with lock-up mechanism)
Gear ratio 1st 2.804
2nd 1.532
3rd 1.000
4th (O/D) 0.705
Reverse 2.394
Oil used Name BESCO ATF III
Q'ty (l) 8.7
Torque converter 2100  150 Stall speed (rpm)
Friction element
Forward clutch C–15
Number of discs Direct clutch C–24
OD direct clutch C–02
Second coast brake B–1 40 mm Band width or
Number of discs
Second brake B–25
Number of discs First and reverse brake B–36
Overdrive brake B–04
Clutch
One-way clutch No.1 F–122
Number of
sprage One-way clutch No.2 F–228
OD one-way clutch F–024
Planetary gear
Front planetary Sun gear 42
Number of teeth Pinion gear 19
Ring gear 79
Rear planetary Sun gear 33
Pinion gear 23
Ring gear 79
O/D planetary Sun gear 33
Pinion gear 23
Ring gear 79

CONSTRUCTION AND FUNCTION 7A1-1

SECTION 7A1
CONSTRUCTION AND FUNCTION
TABLE OF CONTENTS
PAGE
DESCRIPTION ..............................................................................................................................7A1- 3
CONSTRUCTION ....................................................................................................................7A1- 3
MAIN DATA AND SPECIFICATION .....................................................................................7A1- 4
NUMBER PLATE LOCATION ...............................................................................................7A1- 5
ELECTRONIC CONTROL COMPONENTS LOCATION ..................................................7A1- 6
TRANSMISSION CONTROL UNIT (TCM) PERIPHERAL CIRCUIT ..............................7A1- 7
STRUCTURE AND FUNCTION OF COMPONENT ...........................................................7A1- 8
TORQUE CONVERTER (WITH LOCK-UP FUNCTION) ..................................................7A1- 8
OIL PUMP .................................................................................................................................7A1- 9
INPUT SHAFT ..........................................................................................................................7A1- 10
OUTPUT SHAFT ......................................................................................................................7A1- 10
GEAR SHIFTING MECHANISM ............................................................................................7A1- 10
CONTROL VALVE ...................................................................................................................7A1- 14
OIL PASSAGE .........................................................................................................................7A1- 19
PARKING FUNCTION .............................................................................................................7A1- 20
INHIBITOR SWITCH ...............................................................................................................7A1- 21
TURBINE SENSOR .................................................................................................................7A1- 22
SPEED SENSOR .....................................................................................................................7A1- 22
THROTTLE POSITION SENSOR (TPS) .............................................................................7A1- 23
ENGINE SPEED SENSOR (=TDC SENSOR) ....................................................................7A1- 23
BRAKE SWITCH ......................................................................................................................7A1- 24
MODE SELECT SWITCH .......................................................................................................7A1- 24
TRANSMISSION CONTROL MODULE (TCM) ..................................................................7A1- 25
CONTROL MECHANISM ............................................................................................................7A1- 26
CONTENT OF FUNCTION AND CONTROL ......................................................................7A1- 26
CONTROL ITEM, INPUT AND OUTPUT .................................................................... 7A1- 29
LINE PRESSURE CONTROL ..................................................................................... 7A1- 30