2004 ISUZU TF SERIES oil

7A4-10 UNIT REPAIR (JR405E)

39ASSY006



Remove the bearing and the low one-way clutch inner
race from the transmission case.

Remove the bearing from the low one-way clutch inne
r
race.


40ASSY005

21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.


41L&R02

22.Low and reverse brake piston

Force compressed air (329kPa/4.0kg/cm
2) through the
transmission case oil passages.


42ASSY004



Remove the low and reverse brake piston from the
transmission case.

UNIT REPAIR (JR405E) 7A4-11
CONTROL VALVE ASSEMBLY


01CV40

Disassembly steps
1. Oil strainer
Remove the 13 bolts and the oil strainer from the control
valve assembly.


02CV26

2. Harness assembly
Remove the harness assembly.


04CV21

3. Solenoid fixing plate
4. Harness bracket
Remove the 11 bolts and the solenoid fixing plate
together with the harness bracket.


05CV20

7A4-12 UNIT REPAIR (JR405E)

06CV19

5. Solenoid
6. Oil pressure switch Remove the 6 solenoids together and the 3 oil pressure
switchs.


07CV17

7. Control valve upper body
8. Control valve lower body
9. Separation plate
Remove the 17 bolts securing the control valve uppe
r
body, the control valve lower body, and the separation
plate.


08CV16



Separate the upper body, the lower body, and the
separation plate.
NOTE:
Take care not to drop or lose the parts at the inside of the
control valve.

Inspection


Inspect the separation plate for wear and other damage.

UNIT REPAIR (JR405E) 7A4-15
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure
switch connector (wire color: White)
4. Low and reverse brake duty solenoid
connector (wire color: Pink and White)
5. High clutch duty solenoid connector
(wire color: Green and Gray)


6. Lock-up duty solenoid connector (wire
color: Yellow and Black)
7. 2-4 brake duty solenoid connector (wire
color: Blue and Brown)
8. Low clutch duty solenoid connector (wire
color: Orange and Black)
9. Line pressure solenoid connector (wire
color: Pink)

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