oil ISUZU TF SERIES 2004 Workshop Manual

7A4-16 UNIT REPAIR (JR405E)

12CV19

4. Solenoid
5. Oil pressure switch
Install the O-rings to each of the solenoids.

Install the 6 solenoids together and the 3 oil pressure
switchs.
NOTE:
Be sure the high clutch oil pressure switch is marked.

Tighten the bolts to the specified torque.
Torque:
Oil pressure switch bolts – 4.4 N






m (39 Ib






in)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) – 8 N






m (69 Ib






in)
6. Solenoid fixing plate
7. Harness bracket Install the solenoid fixing plate together with the harness
bracket.
Tighten the bolts to the specified torque.

Number Length (Color)
Solenoid fixing plate bolt
(A) 4 16 mm (0.63 in) (Gold)
(B) 7 45 mm (1.77 in) (Silver)

13CV20


Torque: 8 N






m (69 Ib






in)

14CV21



15CV26

8. Harness assembly
Install the harness assembly.

UNIT REPAIR (JR405E) 7A4-17
9. Oil strainer Install the oil strainer.
Tighten the bolts to the specified torque.

Number Length (Color)
Oil strainer bolt
(C) 9 13 mm (0.51 in) (Silver)
(D) 4 45 mm (1.77 in) (Silver)

16CV40


Torque: 8 N






m (69 Ib






in)

7A4-22 UNIT REPAIR (JR405E)
12 High clutch amp 12.0 /
0.472 53.5 /
2.106
13 High clutch
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter (mm
/ in) Linear
diameter (mm
/ in) Number of
coils
1 Manual ---- ---- ---- ----
2 2 – 4 brake accumulator 43.9 / 1.728 11.0 / 0.433 2.0 / 0.079 13.1
3 Low and reverse brake fail (B) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
4 Reverse stall 31.5 / 1.240 7.0 / 0.276 1.0 / 0.039 12.8
5 Low and reverse solenoid brake
accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
6 Pilot 32.0 / 1.260 11.0 / 0.433 1.3 / 0.051 9.2
7 Low clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
8 Low clutch amp (A) 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
9 2 – 4 brake fail (B) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
10 Lock-up control 27.0 / 1.063 14.0 / 0.551 1.1 / 0.043 5.7
11 2 – 4 brake amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
12 High clutch amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
13 High clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
Reassembly steps

Coat the parts with ATF before installing them.

Install the control valve to the upper body.

Install the 11 steel balls and spring to the upper body.

UNIT REPAIR (JR405E) 7A4-23

CONTROL VALVE LOWER BODY

10CV11
Legend
1. Retainer plate, spring, and steel ball
2. Retainer plate, plug, spring, and
pressure regulator valve
3. Retainer plate, spring, and high clutch
accumulator
4. Retainer plate, plug, low and reverse
brake fail valve A, and spring
5. Retainer plate, plug, spring, and fail
valve
6. Retainer plate, plug, low and reverse
brake amp valve, and spring
7. Oil pressure switch
8. Oil filter
9. Solenoid
10. Line pressure solenoid
11. Lock-up solenoid

12. Harness bracket
13. Solenoid fixing plate
14. Harness assembly
15. Retainer plate, plug, spring, and 2-4
brake fail valve A
16. Retainer plate, plug, spring, and low
clutch amp valve B
17. Retainer plate, spring, and torque
converter relief valve
18. Oil strainer
19. Control valve lower body
20. Retainer plate, spring, and 2-4 brake
solenoid accumulator
21. Oil pressure switch

7A4-24 UNIT REPAIR (JR405E)

Disassembly steps

Remove the oil filter from the control valve lower body.

244L300009
Legend
1. Oil filter
2. Separation plate





Remove the control valve from the control valve lower
body.
NOTE:
Place the control valve where it will not get mixed up with
the other parts.

Inspection
Valve
Inspect each of the valves for denting and other damage.
Spring
Inspect each of the springs for wear and fatigue.

UNIT REPAIR (JR405E) 7A4-27

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter (mm
/ in) Linear
diameter (mm
/ in) Number of
coils
14 Pressure relief 49.0 / 1.929 7.6 / 0.299 1.1 / 0.043 17.3
15 Pressure regulator 30.5 / 1.201 14.0 / 0.551 1.4 / 0.055 5.7
16 Low and reverse brake fail (A) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
17 Fail 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
18 Low and reverse brake amp 19.5 / 0.768 7.9 / 0.311 0.5 / 0.020 6.9
19 2 – 4 brake fail (A) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
20 Low clutch amp (B) 26.0 / 1.024 11.0 / 0.433 0.5 / 0.020 6.9
21
Torque converter relief More than 47.2
/ 1.858 9.2 / 0.362 1.6 / 0.063 20.2
22 2 – 4 brake solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
23 High clutch accumulator 51.0 / 2.008 6.5 / 0.256 0.8 / 0.031 23.5

Oil pressure switch
Apply compressed air (392 kPa/4.0 kg/cm2) to the oil pressure
switch to check the oil pressure switch continuity between the
connector and screw.






244L300011

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between harness
terminals 7 and 6 (ground).

Oil temperature sensor resistance: 2,400




2,600 ohms
(20
 )


Solenoid
Measure the resistance of each solenoid.

Resistance:
Brown connector – 3.0
 3.4 ohms (20
 C)
Gray connector – 12.0
 13.2 ohms (20
 C)
White connector – 12.2
 13.4 ohms (20
 C)

Reassembly steps

Coat the parts with ATF before installing them.

Install the control valve to the control valve lower body.

Install the oil filter to the control valve lower body.

7A4-28 UNIT REPAIR (JR405E)
OIL PUMP ASSEMBLY

01PUMP32
Legend
1. Oil seal
2. O-ring (small)
3. Oil pump housing
4. Inner rotor
5. Outer rotor


6. Oil pump cover
7. O-ring (large)
8. Seal ring (large)
9. Seal ring (small)
10. Bearing race


02PUMP07

Disassembly steps
1. Oil pump cover
2. Oil pump housing
Loosen the 8 bolts evenly a little at a time.

UNIT REPAIR (JR405E) 7A4-29

04PUMP10



Separate the oil pump cover from the oil pump housing
by tapping on each of the bolts with a plastic hammer.



06PUMP13

3. Inner rotor
Remove the inner rotor from the oil pump housing.



07PUMP14

4. Outer rotor
Remove the outer rotor form the oil pump housing.



15PUMP18

5. O-ring (small)
Remove the O-ring (small) from the oil pump housing.



08PUMP09

6. O-ring (large)
Remove the O-ring (large) from the oil pump cover.

7A4-30 UNIT REPAIR (JR405E)

09PUMP05

7. Seal ring
Remove the 4 seal rings from the oil pump cover.



11PUMP43

Inspection
Oil pump cover

Install new seal rings to the oil pump cover.
NOTE:
The seal ring with the large inside diameter fits into the
primary mating surface of the cover.

Measure the gap between the seal ring and the seal ring
groove.
If the measured gap is outside the specified range, the
oil pump cover must be replaced.
Seal ring and seal ring groove gap: 0.10






0.25 mm
(0.0039






0.0098 in)

12PUMP45

Inner rotor

Install the inner rotor to the oil pump housing.

Use a straight edge to measure the side clearance
between the oil pump housing and the inner rotor.
If the measured clearance is outside the specified range,
the inner rotor must be replaced.
Oil pump housing and inner rotor side clearance:
0.02~0.04 mm (0.0008~0.0016 in)

13PUMP46

Outer rotor

Install the outer rotor to the oil pump housing.

Measure the gap between the outer rotor and the
crescent.
If the measured gap is outside the specified range, the
outer rotor must be replaced.
Outer rotor and crescent gap:
0.02~0.15 mm (0.0008~0.0059 in)

UNIT REPAIR (JR405E) 7A4-31


Reassembly steps

15PUMP18

1. O-ring (small)
Install new O-ring (small) to the oil pump housing.

16PUMP29

2. Outer rotor
3. Inner rotor Install the outer rotor and the inner rotor to the oil pump
housing.

17PUMP42

NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.

18PUMP07

4. Oil pump cover
5. Oil pump housing Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
Torque: 9 N 


m (78 Ib 


in)



6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring Install the 4 seal rings to the oil pump cover.