clutch ISUZU TROOPER 1995 Owners Manual

AUTOMATIC TRANSMISSION (4L30-E) 7A-181
------1 18. Turbine shaft and overrun clutch ---------------1
_ __1------------:~"""clutch p;ston

Overrun clutch drum
Turbine shaft oil seal ring
Turbine shaft
21. Thrust washer
00 internal gear carrier assembly 1 19. Thrust
be~ ring
'
_]'
' o'"''""'.""elutc~~
Diaphragm spring ~
r~~hp; .. on
I
I '
Fourth clutch piston
23. Retainer
and spring assembly
23.
Snap ring
Fig. 7A-46

7A-182 AUTOMATIC TRANSMISSION (4l30-E)
24. Fourth clutch piston (Fig. 7A-47)
• Inspect piston seals and replace if necessary.
1®-f• Lubricate fitter and install on fourth clutch pis-
ton.
• Install fourth clutch piston in adapter case.
• Remove fitter.
Fourth
clutch piston fitter: J-38554
23. Fourth clutch spring retainer (Fig. 7A-48)
• Install retainer and spring assembly.
• Install snap ring in adapter case.
Fourth clutch position
Fig. 7A-47
1®-1•. Install compressor.
Compress retainer and spring assembly.
• Seat snap ring in groove.
• Remove compressor.
Fourth
clutch spring compressor: J-23327 and
J-23327-90.
J-23327-90 J-23327
Fig. 7A-48
22.
Adapter case and center support assembly
(Fig. 7A .. 49)
• Install selective washer using petroleum jelly.
• Install
two 0-ring seals in main case and
adapter case/main case seal ring.
• Install guide pins.
• Install adapter case complete to main case.
1®1 Guide pin: J-38588
Adapter case
and center support assembly
~~§~~~r---Seal ring
-,
Fig. 7A-49
21. Thrust washer (Fig. 7 A-50)
J-38588
Main case
c::J • Install thrust washer into adapter case, with
~ tangs pointing downwards.
20. Overdrive internal gear (Fig. 7A-50)
19. Thrust bearing assembly (Fig. 7A-50)
18. Turbine shaft and fourth clutch plates (Fig. 7A·
50)
• Preassemble overdrive internal gear and thrust
bearing assembly onto the overrun clutch
assembly complete.
\f!NOTE
Yl Install bearing assembly, black side up. Use
petroleum
jelly to keep assembly in place.
• Complete overdrive carrier and internal gear
assembly into adapter case.
1•1• Install fourth clutch plates in the following
order. Steel, Lined, Steel, Steel, Lined, Steel.
Steel plates
go in with short tang facing
towards valve body surface.
17. Fourth clutch retainer (Fig. 7A-50) ~
1•1• Install fourth clutch retainer.
Notch facing up and positioned towards valve
body surface.
•

~~11. Fourth •
~ clutch
___,,.,.,.,.
retainer
Turbine shaft
& overrun clutch
housing assembly
Fourth clutch
plates
®• I 19. Thrust bearing
18
~Overdrive L' ,
~ernal gear _ ------_j
~ 2l. Thr~st washer
Fig. 7A-50
rfi:il Overdrive clutch end play measurement
~ (Fig. 7A-51 and Fig. 7A-52)
Turbine shaft
J-23085-A
case
Fig. 7A-51
• Install the tool on the adapter case flange and
against the
input shaft.
• Position the inner shaft of the tool against the
thrust surface
of the overrun clutch housing.
• Tighten thumb screw. Remove the tool.
• Measure gap "G". Select appropriate size
washer
as the chart specifies.
• Set selective thrust washer aside.
AUTOMATIC TRANSMISSION (4L30-E) 7A-183
1®.1 Selective washer gaging tool: J-23085-A
J-23085-A
Selective Thrust Washer
Dim.
"G" mm(in) Color
1.53-1.63 (0.060- 0.064) Yellow
1. 72 - 1 .82 (0.068 -0.072) Red
1.91 -2.01 (0.075 -0.079) Black
2.10-2.20 (0.083-0.087) Natural
2.29 -2.39
(0.090 -0.094) Green
2.48 -2.58
(0.098 -0.1 02) Blue
FOLLOWING THE PROCEDURE SHOULD
RESULT
IN FINAL END-PLAY FROM
0.1 mm TO 0.8 mm (0.004" TO 0.03")
Fig. 7A-52
16.
Converter housing and oil pump assembly
(Fig. 7A-53)
• Install outer seal ring and gasket.
• Install selective washer.
W NOTE:
VI Use petroleum jelly to hold selective washer in
place.
• Install
complete converter housing and oil
pump
assembly to adapter case.
• Fit and tighten seven outer 13 mm screws.
~~~ Torque N·m (lb·ft) j 39 (29)

12. Main case valve body (fig. 7A-59)
• Install two check balls (Fig. 7A-60).
• Inspect electrical
connector and seal, replace
if necessary.
• Install electrical 4 pin connector/main case
and
wiring harness.
1®..1 • Install two guide pins into main case.
Guide pin:
J-25025-B
• Install valve
body complete assembly and
manual valve link.
W NOTE:
Valve must be extended as the short end of
manual valve link is connected to the range
selector lever. Long end of link goes into valve.
Fig. 7A-60
• Install
seven 13 mm screws.
~~~ Torque N·mOb·ft) I 20 (15)
• Remove two guide pins.
11.
Servo cover (fig. 7 A-59)
Check ball
• Install servo cover gasket, cover and four 13
mm screws.
~~~ Torque N·mOb·ft) I 25 ( 18)
10. Wiring harness (fig. 7A-59)
• Connect harness to band control and shift
solenoids.
9. Manual detent (fig. 7 A-59)
• Install roller and spring assembly with clip.
Install two 13 mm screws.
~~~ Torque N·mOb·ft) 20 (15)
AUTOMATIC TRANSMISSION (4L30-E) 7A-187
8. Oil filter (Fig. 7 A-59)
• Install oil filter, three 13 mm screws.
~~~ Torque N.m(lb·ft) I 20 (15)
7. Main
case oil pan (Fig. 7 A- 59)
• Install oil pan gasket, magnet, oil pan,
sixteen
10 mm screws.
~~~ Torque N·m(lb·in) I 11 (96)
6. Adapter case valve body (fig. 7 A-59)
• Inspect electrical connector and seal.
Replace
if necessary.
Install electrical five pin connector and
harness
assembly in bottom of adapter
case.
Install gasket, transfer plate, gasket.
• Install adapter case valve body complete
and seven 13 mm screws.
~~~ Torque N.m(lb.ft) I 20 (15)
5. Wiring harness (fig. 7A-59)
• Connect harness assembly to converter
clutch solenoid, and force motor.
4. Adapter case oil pan (fig. 7 A-59)
• Install oil pan gasket, oil pan, twelve 10 mm
screws.
~~~ Torque N·mOb·in) 11 (96)
• Rotate transmission, with bottom pan
facing
down.
• Install seal ring, oil filler tube, 10 mm screw.
~~~ Torque N·mOb·in) I 13 (113)
3. Mode switch and transmission harness
(Fig. 7A-61).
• Install transmission harness.
• Install mode switch, shield and two 10 mm
screws.
• Adjust using setting tool.
Refer to "MODE SWITCH" in this section.
~~~ Torque
Selector shaft nut
10 mm screw
N·mOb·ft)
23 (17)
13 (113 lb·in)

7A-190 AUTOMATIC TRANSMISSION (4L30-E)
OIL PUMP
Disassembly steps 1. Oil pump drive gear 2. Oil pump driven gear 3. Pin 4. Plug 5. Spring 6. Converter clutch control
valve
7. Snap ring 8. Spring seat 9. Spring 10. Throttle signal accumulator piston 11. Sleeve pin 12. Sleeve 13. Boost valve 14. Spring seat 15. Valve spring 16. Spring seat 17. Pressure regulator valve
Reassembly steps
To reassemble, follow the disassembly steps in the
reverse order.
Fig. 7A-64
1+!•1 DISASSEMBLY
1. Oil pump drive gear
2. Oil pump driven gear
3. Pin
4. Plug
5. Spring
6. Converter clutch control valve
7. Snap ring
8. Spring seat
9. Spring
10. Throttle signal accumulator piston
11. Sleeve pin
12. Sleeve
13. Boost valve
14. Spring seat
15.
Valve spring
16. Spring seat
17. Pressure regulator valve
ll..•ltNSPECTION AND REPAIR
Visual check
• If any damage, deformation or local wear is
found in a snap ring, spring, spring retainer
valve,
gear or oil pump, replace it.
l•!•l REASSEMBLY
17. Pressure regulator valve
16. Spring seat
0 • Lubricate and preinstall pressure
L::::J spring seat on valve, with the
1 .. 1 against shoulder.
15. Valve spring
14. Spring seat
13.
Boost valve
12. Sleeve
11. Sleeve pin
10. Throttle signal accumulator piston
9. Spring
8. Spring seat
regulator
flat side
r=1 • Install throttle signal accumulator piston,
t.=..l spring, and spring seat, with the flat side
away from the spring and snap ring.
7. Snap ring
6. Converter clutch control valve
5. Spring
4. Plug
3. Pin
2. Oil pump driven gear
1. Oil pump drive gear

ADAPTER CASE VALVE BODY
AUTOMATIC TRANSMISSION (4L30-E) 7A-193
1
Disassembly steps
1. Converter clutch sole-
noid
2. Retainer
3. Force motor solenoid
4. Spring pin
5. Plug
6. 3/4 accumulator valve
7. 3/4 accumulator control
valve
·
8. Spring pin
9. Spring
10. Retaining ring
11. Feed limit valve
12. Spring pin
13. 0-ring
14. Plug
15. Force motor screen
assembly
Reassembly
steps
To
reassemble, follow the
disassembly steps in the
reverse order.
Fig. 7A-67
l.,!,.l DISASSEMBL V
1. Converter clutch solenoid
• Remove 11 mm bolt from valve body.
• Remove converter control solenoid assembly
with two 0-ring.
2. Retainer
• Remove 11 mm bolt and retainer from valve
body.
3. Force motor solenoid
4. Spring pin
5. Plug
6. 3/4 accumulator valve
7. 3/4 accumulator control valve
8. Spring pin
9.
Spring
10. Retaining ring
11. Feed
limit valve
12. Spring pin
13. 0-ring
14. Plug
15. Force motor screen assembly
• Use 5mm bolt to pull plug.
(L!] INSPECTION AND REPAIR
Inspect for the following and replace any damaged or
worn parts:
• Damage or wear to each valve.
•
Damage in oil passages.
• Cracks or damage to valve body.
• Valve operations.
• Spring fatigue

7A-194 AUTOMATIC TRANSMISSION (4L30-E)
f•!•l REASSEMBLY
15. Force motor screen assembly
14. Plug
13. 0-ring
12. Spring pin
11. Feed
limit valve
10. Retaining ring
9. Spring
8. Spring pin
7. 3/4 accumulator control valve
6. 3/4 accumulator valve
5. Plug
4. Spring pin
3. Force motor solenoid
2. Retainer
r=1 • Plac_e solenoid terminals pointing towards
1=.1 matmg face.
• Install retainer and bolt.
~~~ Torque N·m (lb·in) I 10 (87)
1. Converter clutch solenoid
• Install converter clutch solenoid assembly with
two 0-rings to valve body.
• Install bolt.
~~~ Torque N·m (lb·in) I 10 (87)

THIRD CLUTCH AND SPRAG UNIT
AUTOMATIC TRANSMISSION (4L30-E) 7A-195
Disassembly steps
1. Retaining ring
2. Input sun gear assembly 3. Retaining washer 4. Bearing 5. Thrust washer 6. Clutch plates 7. Third clutch drum
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.
Fig. 7A-68
1•! .. 1 DISASSEMBL V
1. Retaining ring (Fig. 7A-69)
• Place the third clutch housing and intermediate
shaft
assembly upright, using the overdrive
internal gear as a support.
I®J • Locate the end of the sprag retaining ring.
Compress near the
end, using a screwdriver
through the side
slot and slide one tool blade
between ring and housing to hold the ring clear
of the groove.
• Repeat with a second tool blade near the other
end
of the retaining ring.
• Repeat with a third tool blade opposite the first
two.
• Repeat with two further blades equally spaced
apart.
Third
clutch retaining ring compressor: J-38450
2. Input sun gear assembly
3.
4.
5.
6.
7.
• Pull the input sun gear assembly unit until the
sprag retaining ring
clears the ring groove.
Retaining washer
Bearing
Thrust washer
Clutch plates
Third clutch drum
Fig. 7A-69
Third clutch
drum
assembly
00. internal

7A-196 AUTOMATIC TRANSMISSION (4L30-E)
IL•IINSPECTION AND REPAIR
Visual check
• If any damage, deformation or local wear is
found in a bearing, thrust washer, clutch plates
or third clutch drum, replace it.
l•!•l REASSEMBLY
7. Third clutch drum
6. Clutch plates
• Place third clutch housing and intermediate
shaft assembly upright, using the overdrive
internal gear
as a support.
, .. , • Install third clutch spring cushion plate,
bevel face
down.
• Install third clutch plates into clutch housing.
Start
with the steel clutch plate and alternate
with lined plates.
5.
Thrust washer
4. Bearing
3. Retaining washer
2. Input sun gear assembly (fig. 7A-70)
1. Retaining ring
• Fully engage the sprag assembly hub
splines into the third clutch inner tangs.
Simultaneously rotate the outer sprag race
to engage into the third clutch housing.
1®.1 • Install a tool blade at each extremity of the
retaining ring.
• Compress the retaining ring with a screw­
driver opposite the tool blades while
pushing down on the outer sprag race.
THIRD CLUTCH
Fig. 7A-71
• Engage retaining ring into groove.
• Remove tool blades.
Third clutch retaining ring compressor: J-38450
J.4---J-38450
~~--oo. internal
gear
Fig. 7A-70
Disassembly steps 1. Retaining ring 2. Spring seat 3. Springs 4. Piston
Reassembly steps
To reassemble, follow the
disassembly steps in the
reverse order.
*; Repair kit

l•!•l DISASSEMBLY
1. Retaining ring (Fig. 7A·72)
1®.1• Compress spring seat using the tool.
U7 NOTE:
VI Do not over-stress the springs and seat. This will
cause damage to the spring seat.
• Remove retaining ring.
• Release the spring seat.
U7 NOTE:
VI Do not let the spring seat catch in the ring groove.
Spring compressor: J-23075
Adapter: J-23075-12
Fig. 7A-72
2. Spring seat
3. Springs
4. Piston
~ INSPECTION AND REPAIR
Visual check
J-23075-12
J-23075
• If any damage, deformation or local wear is found
in a retaining ring, return spring, piston
seals or
spring seat, replace it.
Operation check
• Shake piston and listen for check ball movement.
Replace piston if check ball is missing or falls out.
AUTOMATIC TRANSMISSION (4L30-E) 7A-197
l•!•l REASSEMBLY
4. Piston (Fig. 7A·73)
r=1 • The lip of the seals must point toward the front
t=J of the transmission. Lubricate the lip seal with
loe:r·l transmission fluid.
~·
Install piston assembly into the third clutch
drum. Use installer to protect the outer seal
during installation.
Third clutch piston installer: J-23084
J-23084
Third clutch----•n drum
Fig. 7A-73
3. Springs
2. Spring seat
1. Retaining ring
• Place retaining ring onto spring seat.
~ • Co~press the piston springs, using the piston
sprmg compressor.
WcAUTION:
Do not over-stress the springs and seat. Do not let the
spring seat catch in the ring groove. This may cause
damage to the spring seat.
• Install spring seat retaining ring.
• Remove the piston spring compressor.
Spring compressor: J-23075
Adapter: J-23075-12