2004 ISUZU TF SERIES brake

UNIT REPAIR (AW30–40LE) 7A4–81
Rear Planetary Gear Assembly and Output Shaft
Disassembled View
2 47R20 0005
E nd O FCallo ut
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.
RUW3 7A SH00 4701
E nd OFCa llou t
Legend
(1) Lock
(2) Free

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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E nd OFCa llou t
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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UNIT REPAIR (AW30–40LE) 7A4–87
First and Reverse Brake (B–3)
Disassembled View
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E nd O FCallo ut
Legend
(1) Thrust bearing and race
(2) Snap ring
(3) Piston return spring
(4) First and reverse brake piston No.2(5) O-ring
(6) Reaction sleeve
(7) O-ring
(8) First and reverse brake piston No.1
(9) O-ring

7A4–88 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove assembled thrust bearing and race from
transmission case.
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2. Check first and reverse brake piston movement.
Make sure that first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
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3. Set special tool on the spring retainer, and
compress the return spring.
Spring compressor: J–25048
Remove the snap ring with snap ring pliers.
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4. Remove the piston return spring.
5. Remove the first and reverse brake piston No.2.
Holding the first and reverse brake piston No.2 by
hand, apply compressed air to the transmission
case to remove the first and reverse brake piston
No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air,
lift the piston out with needle-nose pliers.
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UNIT REPAIR (AW30–40LE) 7A4–89
6. Remove the O-ring from first and reverse brake
piston No.2.
7. Remove the reaction sleeve.
Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: J–37236
RUW 37A SH00 330 1
8. Remove the O-ring from reaction sleeve.
9. Remove the first and reverse brake piston No.1.
Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the
transmission case.
Piston puller: J–37237
RUW 37A SH00 340 1
10. Remove the O-rings from first and reverse brake
pistion No.1.
Reassembly
1. Coat three new O-rings with ATF.
Install the two O-rings on the No.1 piston.
2. Install the O-ring on the reaction sleeve.
3. Install the first and reverse brake piston No.1 to the
reaction sleeve.
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4. Coat a new O-ring with ATF and install it on the first
and reverse brake piston No.2.
5. Install the first and reverse brake piston No.1 with
reaction sleeve onto the first and reverse brake
piston No.2.
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7A4–90 UNIT REPAIR (AW30–40LE)
6. Align the teeth of the first and reverse brake piston
No.2 into the proper grooves.
Being careful not to damage the O-rings, press in
the first and reverse brake piston No.2 with No.1
into the transmission case.
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7. Place piston return spring onto first and reverse
brake piston No.2.
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8. Set special tool as shown, and compress the return
spring with special tool.
Spring compressor: J–25048
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
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9. Check first and reverse brake piston movement.
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
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