oil ISUZU TF SERIES 2004 Workshop Manual

UNIT REPAIR (AW30–40LE) 7A4–73
Planetary Sun Gear and No.1 One-Way Clutch
Disassembled View
2 48R20 0005
E nd O FCallo ut
Legend
(1) One-way clutch and second brake hub
(2) Thrust washer (plastic)
(3) Oil seal ring (Metal)(4) Snap ring
(5) Sun gear input drum
(6) Snap ring
(7) Planetary sun gear

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).
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5. Remove the snap ring with snap ring pliers.
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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.
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Legend
(1) Free
(2) Lock

UNIT REPAIR (AW30–40LE) 7A4–75
Reassembly
1. Install snap ring to planetary sun gear.
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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.
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3. Install snap ring with snap ring pliers.
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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.
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UNIT REPAIR (AW30–40LE) 7A4–81
Rear Planetary Gear Assembly and Output Shaft
Disassembled View
2 47R20 0005
E nd O FCallo ut
Legend
(1) Second brake assembly
(2) Output shaft
(3) Oil seal ring
(4) Disc, plate and flange (B–3)
Seven discs and seven plates
(5) Rear planetary gear assembly
(6) One-way clutch inner race
(7) Snap ring(8) One-way clutch
(9) Thrust washer (Plastic)
(10) Thrust washer (Plastic)
(11) Rear planetary gear
(12) Thrust bearing and race
(13) Snap ring
(14) Ring gear flange
(15) Rear planetary ring gear

7A4–82 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove second brake assembly from output shaft.
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2. Remove oil seal ring from output shaft.
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3. Remove the seven discs, seven plates and flange
(B–3).4. Remove rear planetary gear from rear planetary ring
gear.
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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
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Legend
(1) Lock
(2) Free

7A4–86 UNIT REPAIR (AW30–40LE)
Install six clutch discs and six brake plates
alternately, starting with clutch disc, onto the rear
planetary gear assembly.
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11. Coat the oil seal ring with ATF and install it to the
output shaft.
NOTE: Do not spread the ring ends too much.
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12. Install output shaft into rear planetary gear
assembly.
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13. Install second brake assembly to output shaft.
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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

UNIT REPAIR (AW30–40LE) 7A4–121
Transmission Case
Disassembled View
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Disassembly
1. Using a chisel, cut off the spacer and remove it from
the shaft.
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Legend
(1) Spacer
(2) Pin
(3) Manual valve lever shaft(4) Manual valve lever
(5) Oil seal
(6) Oil seal

7A4–122 UNIT REPAIR (AW30–40LE)
2. Using a punch, drive out the pin.
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3. Pull the manual valve lever shaft out through the
case by the threads.
4. Take out the manual valve lever.
5. Using a screwdriver, remove the oil seals.
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Reassembly
1. Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : J–37232–2
RTW3 7A SH00 0701
2. Assemble a new spacer to the manual valve lever.
3. Install the manual valve lever shaft to the
transmission case through the manual valve lever
by the threads.
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