2004 ISUZU TF SERIES Transmission

UNIT REPAIR (AW30–40LE) 7A4–21
14. Using snap ring pliers, remove the snap ring.
24 8RY 0 000 6
15. Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
24 8RY 0 000 7
16. Remove the direct clutch and forward clutch from
the transmission case.
24 8RY 0 0008
17. Remove the E-ring from the pin.
Remove the pin from the brake band.
24 8RY 0 0009

7A4–22 UNIT REPAIR (AW30–40LE)
18. Remove the second coast brake band from the
transmission case.
24 8RY 0 001 0
19. Remove the front planetary ring gear from the
transmission case.
24 7RY 0 000 4
20. Remove the bearing and race.
24 7RY 0 0005
21. Remove the race.
24 7RY 0 0006
22. Using snap ring pliers, remove the snap ring.
24 8RY 0 0011

UNIT REPAIR (AW30–40LE) 7A4–23
NOTE: Hold the output shaft to prevent it from falling.
The output shaft falls when the snap ring is removed.
23. Remove the front planetary gear from the
transmission case.
24 7RY 0 000 7
24. Remove sun gear input drum and one-way clutch.
24 8RY 0 001 2
25. Using two screwdrivers, remove the snap ring.
24 8RY 0 0014
26. Remove, five discs and six plates (B–2).
24 8RY 0 0015

7A4–24 UNIT REPAIR (AW30–40LE)
27. Check pack clearance of first and reverse brake (B–
3)
Using a feeler gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.6 – 1.12 mm (0.0236 – 0.0440 in)
If the values are nonstandard, replace the discs.
24 8RY 0 001 6
28. Using snap ring pliers, remove the snap ring.
24 8RY 0 001 7
29. Remove the rear planetary gear, second brake drum
and output shaft as an assembly.
2 47R20 0001
30. Remove the assembled thrust bearing and race
from the transmission case.
24 8RY 0 0018

UNIT REPAIR (AW30–40LE) 7A4–25
Reassembly
1. Coat the assembled bearing and race with
petroleum jelly and install it onto the transmission
case.
A ssembled bearing and race (Reference)
24 7RY 0 000 8
2. Install the rear planetary gear, second brake drum
and output shaft.
Align the teeth of the second brake drum,
flanges, discs and plates as shown in the figure.
24 7RY 0 000 9
Align the splines of the transmission case and the
assembled rear planetary gear, second brake
drum and output shaft, indicated by A in the
figure.
24 7RY 0 0010
3. Using snap ring pliers, install the snap ring.
24 6RY 0 0003
Bearing and race Diameter
Inside 39.38 mm (1.550 in)
Outside 58.15 mm (2.289 in)

7A4–26 UNIT REPAIR (AW30–40LE)
4. Check pack clearance of first and reverse brake.
Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.60 – 1.12 mm (0.0236 – 0.0440 in)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 001 6
5. Install second brake piston sleeve.
24 6RY 0 000 4
6. Install one-way clutch in the transmission case.
24 7RY 0 0011
7. Install discs and plates (B–2).
Instal the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)
24 6RY 0 0005

UNIT REPAIR (AW30–40LE) 7A4–27
8. Install the snap ring.
24 8RY 0 001 4
9. While turning the sun gear input drum clockwise,
install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.
24 8RY 0 002 0
10. Install the front planetary gear and bearing to the
sun gear.
NOTE: Confirm the bearing and race is installed
correctly.
Bearing and race diameter (Reference)
24 7RY 0 0012With wooden blocks under the output shaft, stand
the transmission on the output shaft.
24 7RY 0 0013
Inside Outside
Bearing 35.6 mm (1.40 in) 47.7 mm (1.88 in)
Race 33.7 mm (1.33 in) 47.6 mm (1.87 in)

7A4–28 UNIT REPAIR (AW30–40LE)
11. Using snap ring pliers, install the snap ring.
24 8RY 0 0011
12. Coat the bearing race with petroleum jelly and install
it onto the front planetary gear.
Bearing race diameter (Reference)
24 7RY 0 001 4
13. Insert the second coast brake band to the
transmission case.
24 8RY 0 0010
14. Install the E-ring and pin.
Install the pin through the brake band.
24 8RY 0 0021
Bearing race Diameter
Inside 34.3 mm (1.350 in)
Outside 47.8 mm (1.882 in)