2004 ISUZU TF SERIES Check ball

FRONT SUSPENSION 3C-59
5. NOISES

Checkpoint Trouble Cause Countermeasure



Lubricating oil and grease for
upper and lower ball joint


Shock absorber


Stabilizer fixing nuts and bolts


Upper and lower links
bushings


Replace


Replace


Retighten


Replace


Insufficient


Faulty


Loose


Worn


Shock absorber fixing nut and
bolt

Retighten

Loose

Continued on the next pageOK OK OK OK
NG NG NG NG NG
OK

Upper and lower ball joint

Replace

Damaged
NG

TRANSFER CASE 7D-21

Oil Pump


Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play


Set a dial indicator to the clutch hub to be measured.


Move the clutch hub as far as possible to both the
right and the left.

Note the dial indicator reading.


If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch hub spline play
Standard : 0 – 0.1 mm (0 – 0.004 in)
Limit : 0.2 mm (0.008 in)

226RS042
Bearings
1.
Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2.
Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.




Ball Bearing Play
1.
Use a dial indicator to measure the ball bearing play.
2.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)


226R3043

Synchronizers
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together as
originally assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:


Teeth for wear, scuffs, nicks, burrs or breaks.


Keys and springs for wear, cracks or distortion,
replace if these conditions are present.


If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace
the component.

UNIT REPAIR (AW30–40LE) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 002 7
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
25 2RY 0 002 8
3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
25 2RY 0 0029
4. Check OD direct clutch drum bushings.
Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in)
If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
25 2L10 0009

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
24 8RY 0 003 0
8. Remove two O-rings from piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)
24 7RY 0 003 4
2. Check discs.
Using micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 0027
3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031

7A4–66 UNIT REPAIR (AW30–40LE)
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048
24 8RY 0 000 3
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
24 8RY 0 004 2
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from
forward clutch drum.
Inspection and Repair
1. Check forward clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031
2. Check forward clutch drum bushing.
Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 in)
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
24 8RY 0 0043
3. 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.

UNIT REPAIR (AW30–40LE) 7A4–93
Disassembly
1. Remove detent spring from valve body.
2 40R20 004 0
2. Remove the manual shift valve.
3. Remove the upper valve body.
4. Remove the no.1 gasket (Upper valve body side).
5. Remove the valve body plate.
Turn over assembly and remove thirty bolts.
2 44R20 004 9
6. Remove the clamp.7. Remove the pressure control solenoid.
Hold the valve body plate to the upper valve body.
Lift off upper valve body and plate as a single unit.
NOTE: Be careful that the check balls and strainers do
not fall out.
2 44R20 0061
8. Remove the no.2 gasket (Lower valve body side).
9. Remove the lower valve body.
Reassembly
1. Position a new No.1 gasket (1) on upper valve body.
Align the No.1 gasket at each bolt hole.
2. Position valve body plate (2) on No.1 gasket (1).
Align the plate at each bolt hole.
3. Position a new No.2 gasket (3) on valve body plate
(2).
Align the No.2 gasket at each bolt hole.
2 44R20 0073

UNIT REPAIR (AW30–40LE) 7A4–103
18. Remove the sleeve(31) with the plungers(32)(33),
spring(34) and washer.
Remove the two plungers(32)(33) from the sleeve.
Remove the primary regulator valve(36) from the
valve body(37).
2 44R20 006 0
Inspection and Repair
1. Inspect strainer
Inspect strainer for residual adhesive and damage,
and clean and replace as necessary.
2 44R20 005 1
2. Inspect valve springs
Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than shown below.
mm (in)
2 44R20 0077
SpringFree
lengthColor
(1) By-pass valve21.3
(0.839 )YELLOW
(2) Steel ball20.5
(0.807 )WHITE
(3) 1–2 shift valve 30.8
(1.213 )PURPLE
(4) Low coast modulator valve30.4
(1.197 )LIGHT
GREEN
(5) Accumulator control valve33.8
(1.331)—
(6) Solenoid modulator valve 26.6
(1.047)LIGHT
BLUE
(7) Cut back valve 34.0
(1.339)DARK
BLUE
(8) Primary regulator valve38.58
(1.519)WITHE