2004 ISUZU TF SERIES clutch

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.
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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

7A4–76 UNIT REPAIR (AW30–40LE)
5. Install thrust washer (plastic).
NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
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6. Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
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7. 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.
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Legend
(1) Free
(2) Lock

UNIT REPAIR (AW30–40LE) 7A4–81
Rear Planetary Gear Assembly and Output Shaft
Disassembled View
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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.
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Legend
(1) Lock
(2) Free

UNIT REPAIR (AW30–40LE) 7A4–83
6. Remove the one-way clutch inner race from the rear
planetary gear.
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7. Remove the snap ring with a screwdriver.
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8. Remove the one-way clutch with retainers from the
planetary gear.
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9. Remove the thrust washer (plastic) from front side
of rear planetary gear.
10. Remove the thrust washer (plastic) from rear side of
rear planetary gear.
11. Remove the thrust bearing and race from front side
of ring gear flange.
12. Remove the snap ring from rear planetary ring gear.
13. Remove the ring gear flange from rear planetary
ring gear.
14. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.
Before assembling new discs, soak them in ATF
for at least fifteen minutes.
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7A4–84 UNIT REPAIR (AW30–40LE)
Reassembly
1. Install ring gear flange to the rear planetary ring
gear.
2. Install snap ring to the rear planetary ring gear.
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3. Coat the races and bearing with petroleum jelly, and
install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)
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4. Coat the thrust washers (plastic) with petroleum
jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE: Make sure that the lugs fit into the cutout
portions on the rear planetary gear.
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5. Install the one-way clutch with the flanged side
facing upward onto the rear planetary gear.
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6. Install snap ring.
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Inside Outside
Race (A) 28.5 mm (1.122 in) 44.2 mm (1.740 in)
Bearing and
race (B)27.7 mm (1.091 in) 44.2 mm (1.740 in)

UNIT REPAIR (AW30–40LE) 7A4–85
7. While turning counterclockwise, install one-way
clutch inner race to rear planetary gear.
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8. Check operation of 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.
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9. Install rear planetary gear onto rear planetary ring
gear.
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10. Install the disc, plate and flange (B–3).
Install a brake flange onto the rear planetary gear
assembly.
Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
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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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