automatic transmission ISUZU TROOPER 1995 Workshop Manual

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

7A-198 AUTOMATIC TRANSMISSION (4L30-E)
SPRAG UNIT
2. Sprag assembly
3. Sun gear assembly
Fig. 7A-74
1.,!•1 DISASSEMBLY
1. Sprag outer race
2.
Sprag assembly
• Remove sprag outer race and sprag assembly
from third clutch hub and sun gear assembly.
3. Sun gear assembly
(1!] INSPECTION AND REPAIR
Visual check
• If any damage, deformation or local wear is found
in a sun gear, sprag assembly or sprag outer race,
replace it.
1•! .. 1 REASSEMBLY
3. Sun gear assembly
2. Sprag assembly
• Install sprag assembly onto the sun gear.
\fl NOTE:
VI Flared shoulder of the sprag cage faces the sun
gear.
This procedure
must be followed exactly to be
sure that the sprag assembly is
installed properly.
1. Sprag outer race (Fig. 7A-75)
• Install outer sprag race assembly over the
sprag cage assembly.
1•1• Place third clutch hub and sun gear assembly
on a
1Fiat surface, sun gear facing up. Place
sprag outer race and sprag assembly over the
sun
g,ear assembly, push down and turn the
input sun counterclockwise at the same time.
\fl NOTE:
VI Check correct rotation by holding the sun gear in
your left hand and turning the outer race. The
outer sprag race should turn freely
towards you
and
lock turning away from you.
Fig. 7A-75
•

SECOND CLUTCH
5 4
1•!•1 DISASSEMBLY
1. Retaining ring
2. Ring gear
3. Retaining ring
4. Spacer
5.
Clutch plates
6. Waved washer
7. Retaining ring (fig. 7A-77)
~~~ • Compress the spring seat.
Compressor: J-23327
Fig. 7A-77
AUTOMATIC TRANSMISSION (4L30-E) 7 A-199
'
__ _j
1
Fig. 7A-76
8.
Spring seat
9.
Springs
10. Piston
11. Second
clutch drum
Disassembly steps 1. Retaining ring 2. Ring gear 3. Retaining ring 4. Spacer 5. Clutch plates 6. Waved washer 7. Retaining ring 8. Spring seat 9. Springs 10. Piston 11. Second clutch drum
Reassembly steps
To reassemble, follow the
disassembly steps in the
reverse order.
*; Repair kit
I L•IINSPECTION AND REPAIR
Visual check
• If any damage, deformation or local wear is
found in a retaining ring, ring gear, spacer,
clutch plates, piston seals, return spring or
spring seat, replace it.
Operation check
• Shake piston and listen for check ball movement.
Movement indicates proper check
ball operation.
Replace piston if check ball is missing or falls out.

7 A-200 AUTOMATIC TRANSMISSION (4L30-E)
l•!•l REASSEMBLY
11. Second clutch drum
10. Piston (Fig. 7A-78)
0 • Install piston assembly into the second
t..::::::.:J clutch drum. Lubricate the lip seal with
1®..1 liberal amounts of transmission fluid. Use
the installer to protect the outer piston lip
seal.
W NOTE:
Lip of the seals point toward front of trans­
mission.
Second clutch piston installer: J-23080-A
Seal ring
3. Retaining ring
2. Ring gear
1. Retaining ring
3-4 ACCUMULATOR PISTON
,Snap ring
Cover
* *
<·-' ~·· ··~
Spring Jr-J
1
t -;;~~H -~, ~:·.-... , ' ~ '-'FJ:
Pi!;ton * ~~+_z.~~
*;Repair kit
Fig. 7A-79
1•!•1 DISASSEMBLY
1. Snap ring (Fig. 7 A-80)
l?.i\1 • Install! cover compressor on adapter case.
~ Compress piston cover. Remove snap ring.
Drum Compressor: J-38559-A
Fig. 7A-78
9. Springs
8. Spring seat
7. Retaining ring
• Install twenty-two piston springs and spring
seat on the second clutch piston. Place
retaining ring onto spring seat.
1 ®..I • Use the compressor to compress the piston
springs.
Compressor: J-23327
w NOTE:
Do not let spring seat catch in ring groove.
6. Waved plate
5. Clutch plates
• Install clutch plates. Start with a steel plate
and alternate with lined plates.
IEtl Align second clutch inner tangs.
4. Spacer
r::1 • Install spacer, with the fluted end toward
t.:=.l clutch plates.
Adapter case
Fig. 7A-80
•

2. Cover (Fig. 7A-81)
1®.1 • Install cover remover to center hole of
cover.
Use slide
hammer to remove cover.
Cover
remover: J-41096
Adapter: J-38584
Slide
hammer : J-23907
Snap ring
Fig. 7A-81
3. Spring
4. Piston
I L•IINSPECTION AND REPAIR
Visual Check
• If any damage, deformation or wear is found in
a return
spring, piston or piston cover, replace
it.
AUTOMATIC TRANSMISSION (4L30-E) 7 A-201
l•!•l REASSEMBLY
4. Piston (Fig. 7 A-82)
l"'iQ\1 • Place the fitter into a~~ptor ca~e and. push
~ the piston into pos1t1on, usmg su1table
diameter tube.
Piston fitter: J-38553
J-38553 Adapter case
Fig. 7A-82
3. Spring
2. Cover (Fig. 7 A-83)
l"'iQ\1 • Install cover, using compressor tool.
~ Compressor: J-38559-A
Adapter case
Piston cover
Fig. 7A-83
1. Snap ring
• Install snap ring in groove.

7A-202 AUTOMATIC TRANSMISSION (4l30-E)
REVERSE CLUTCH PISTON AND CENTER SUPPORT
9
i
____ j
Disassembly steps 1. Retaining ring 2. Spring seat
3. Springs 4. Piston
5. Center support 6. Gasket 7. Transfer plate
8. Gasket 9. Restrictor 10. Retainer plate
11. Plug 12. Spring
RusMmbly steps To reassemble, follow the
disassembly steps in the
reverse order.
13. Overrun lock out valve
Fig. 7A-84
1•! .. 1 DISASSEMBLY
1. Retaining ring (fig. 7A-85)
• Install the tool on spring seat.
liC\1 • Compress the spring seat.
~ Compressor: J-23327
W NOTE:
¥1 Do not over-stress the springs and seat, as this
will cause damage to the spring seat.
Fig.
7A-85
2. Spring seat
3. Springs
4. Piston
5. Center support
• Remove 8 bolts from center support.
center· support from adapter case.
6. Gasket
7. Transfer plate
8. Gasket
9. Restrict<,r
10. Retainer plate
11. Plug
12. Spring
13. Overrun lock out valve
IL•IINSPECTION AND REPAIR
Visual check Remove
•
If any damage, deformation or local wear is found
in a retaining ring, return spring, spring retainer,
~
piston or center support, replace it.
..

7 A-204 AUTOMATIC TRANSMISSION (4l30-E)
OVERRUN CLUTCH AND TURBINE SHAFT
I
I '
.L.llL
14
-·
13 L~L
Disassembly steps 1. Snap ring 2. Overdrive carrier assembly 3. Sun gear 4. Turbine shaft
---------___________________________ _! 5. Snap ring 6. Backing plate 7. Clutch plates 7 8. Snap ring 9. Overrun roller clutch cam 10. Roller clutch assembly 11. Overrun clutch release spring retainer 12. Diaphragm spring 13. Piston 14. Overrun clutch drum 15. Turbine shaft seal rings
Reassembly steps
To reassemble, follow the disassembly steps in the
reverse order.
Fig. 7A-87
EE DISASSEMBLY
1. Snap ring (fig. 7 A-88)
• Position overrun clutch assembly upright,
using the overdrive
internal gear as a support.
• Remove snap ring.
Fig. 7A-88 2.
Overdrive carrier
assembly
3. Sun gear
4. Turbine shaft
5. Snap ring
6. Backing plate
7. Clutch plates
8. Snap ring (fig. 7 A-891
• Compress piston return spring with com-
pressor.
1®..1 Compressor: J-23327-91
9. Overrun roller clutch cam
10. Roller clutch assembly
11. Overrun clutch release spring retainer
12. Diaphragm spring
13. Piston
14. Overrun clutch drum
15. Turbine shaft seal rings
•

J-23327-91
Roller clutch assembiy
Fig. 7A-89
li:!] INSPECTION AND REPAIR
Overdrive carrier check (Fig. 7A-90)
Snap ring
1@1• Check pinion end play with a feeler gage.
Clearance mm (in) I 0.24-0.64 (0.0094-0.025)
If clearance
is outside specified value, replace
overdrive carrier assembly.
Overdrive carrier
on
Fig. 7A-90
Visual
check
• If any damage, deformation or local wear is found
in a snap ring, diaphragm spring,
or spring
retainer,
roller clutch assembly, turbine shaft,
piston
or clutch plates, replace it.
AUTOMATIC TRANSMISSION (4L30·E) 7A-205
l•!•l REASSEMBL V
15. Turbine shaft seal rings (Fig. 7 A-91)
• Install seals with grease (petroleum jelly).
Turbine shaft
Fig. 7A-91
14. Overrun clutch drum
13. Piston (Fig. 7A-92, 7A-93)
Front view
1®..1• Install the inner installer on the drum.
• Pre-install piston into outer installer.
• Install
overrun clutch piston assembly. Use the
outer
installer while pushing piston into drum.
Installer: J-38555
Fig. 7A-92