oil ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–21
14. Using snap ring pliers, remove the snap ring.
24 8RY 0 000 6
15. Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
24 8RY 0 000 7
16. Remove the direct clutch and forward clutch from
the transmission case.
24 8RY 0 0008
17. Remove the E-ring from the pin.
Remove the pin from the brake band.
24 8RY 0 0009

UNIT REPAIR (AW30–40LE) 7A4–31
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
A ssembled bearing and race diameter
(Reference)
24 8RY 0 002 5
20. Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
RUW 37A SH00 440 1
E nd OFCa llou t
21. Coat two new oil seals with ATF and install them to
the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
24 8RY 0 0027
22. Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod
as shown in the figure.
24 8RY 0 0005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 11 4 p s i )
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in) Inside Outside
Bearing
and race33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod

7A4–32 UNIT REPAIR (AW30–40LE)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 000 4
23. Coat the race with petroleum jelly and install it onto
the overdrive support assembly.
Race diameter (Reference)
25 2RY 0 000 7
24. Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.
25 2RY 0 0005
25. Using snap ring pliers, install the snap ring as
shown in the figure.
25 2RY 0 0008
Inside Outside
Race 36.7 mm (1.44 in) 50.8 mm (2.00 in)

7A4–36 UNIT REPAIR (AW30–40LE)
34. Install the overdrive planetary gear and direct clutch.
2 52L10 000 1
35. Coat the assembled bearing and race with
petroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
2 52L10 001 8
36. Coat the race with petroleum jelly and install it onto
the oil pump.
Race diameter (Reference)
25 2RY 0 0014
37. Coat the O-ring with ATF and install it around the
pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CA UTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N·m (16 lb ft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.
24 1RY 0 0003
Inside Outside
Bearing
and race28.9 mm (1.138 in) 50.2 mm (1.976 in)
Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

7A4–38 UNIT REPAIR (AW30–40LE)
Oil Pump
Disassembly View
2 41R20 0003
E nd O FCallo ut
Disassembly
1. Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
24 1RY 0 0005
Legend
(1) Oil seal ring
(2) O-ring
(3) Stator shaft(4) Oil pump drive gear
(5) Oil pump driven gear
(6) Oil pump body

UNIT REPAIR (AW30–40LE) 7A4–39
2. Remove the O-ring.
3. Remove the stator shaft.
4. Remove the oil pump drive gear.
5. Remove the oil pump driven gear.
6. Remove the oil pump body.
Remove 13 bolts, and then remove the stator shaft
from oil pump body.
Then remove drive and driven gear.
24 1RY 0 000 6
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check oil pump body bushing.
Using a dial indicator, measure the inside diameter
of the oil pump body bushing.
Maximum inside diameter: 38.19 mm (1.5035 in)
If the inside diameter is greater than the maximum,
replace the oil pump body.
24 1RY 0 000 7
2. Check stator shaft bushing.
Using a dial indicator, measure the inside diameter
of the stator shaft bushing.
Maximum inside diameter: Front side: 21.58 mm
(0.8496 in)
Maximum inside diameter: Rear side: 27.08 mm
(1.0661 in)
If the inside diameter is greater than the maximum,
replace the stator shaft.
24 1RY 0 0008
3. Check tip clearance of both gears.
Measure between the gear teeth and the
cresent-shaped part of the pump body.
Standard tip clearance: 0.11 – 0.14 mm (0.0043 –
0.0055 in)
Maximum tip clearance: 0.19 mm (0.0075 in)
If the tip clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
24 1RY 0 0009

7A4–40 UNIT REPAIR (AW30–40LE)
4. Check body clearance of driven gear.
Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
Standard body clearance: 0.07 – 0.15 mm (0.0028
– 0.0059 in)
Maximum body clearance: 0.2 mm (0.0079 in)
If the body clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
24 1RY 0 001 0
5. Check side clearance of both gears.
Using a steel straightedge and a feeler gauge,
measure the side clearance of both gears.
Standard side clearance: 0.02 – 0.05 mm (0.0008 –
0.0020 in)
Maximum side clearance: 0.1 mm (0.004 in)
If the side clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
24 1RY 0 0011
6. Check oil seal.
Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
24 1RY 0 0012Using special tool, install a new oil seal.
The oil seal end should be flush with the outer edge
of the pump body.
Oil seal installer : J–9617
Coat the oil seal lip with multipurpose grease.
24 1RY 0 0013

UNIT REPAIR (AW30–40LE) 7A4–41
Reassembly
1. Place the oil pump body on the torque converter.
2. Coat the driven gear and drive gear with ATF.
3. Install the driven gear and drive gear.
24 1RY 0 001 4
4. Align the stator shaft with the bolt holes.
Tighten the thirteen bolts.
Torque: 10 N·m (87Ibin)
24 1RY 0 000 6
5. Install the oil seal ring.
Coat the oil seal rings with ATF.
Contract the oil seal rings as shown, and install
them onto the stator shaft.
NOTE: Do not spread the ring ends too much.
24 1RY 0 0015
6. Coat a new O-ring with ATF and install it to the oil
pump body.
O-ring size (Reference)
24 1RY 0 0016
Inside diameter 204.9 mm (8.067 in)
Thickness 3.5 mm (0.138 in)

7A4–42 UNIT REPAIR (AW30–40LE)
7. Check oil pump drive gear rotation.
Make sure the drive gear rotates smoothly when
installed to the torque converter.
24 1RY 0 001 7