2004 ISUZU TF SERIES transmission

7A4–30 UNIT REPAIR (AW30–40LE)
17. Align the spline of the front planetary gear with the
flukes of the discs and install the front planetary
gear to the forward clutch.
24 7RY 0 001 7
18. Coat the bearing and race with petroleum jelly and
install them onto the ring gear.
Bearing and race diameter (Reference)
24 7RY 0 001 9
19. Install the assembled direct clutch, forward clutch
and front planetary ring gear into the transmission
case.
24 7RY 0 0018
Using vernier calipers, measure the distance
between the sun gear input drum and direct
clutch drum as shown in the figure.
Height: 2.5– 4.5 mm (0.098 – 0.177 in)
If the values are nonstandard, check for an
improper installation.
24 8RY 0 0024
Inside Outside
Bearing 35.15 mm (1.384 in) 53.65 mm (2.112 in)
Race 35.15 mm (1.384 in) 53.65 mm (2.112 in)

UNIT REPAIR (AW30–40LE) 7A4–31
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
A ssembled bearing and race diameter
(Reference)
24 8RY 0 002 5
20. Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
RUW 37A SH00 440 1
E nd OFCa llou t
21. Coat two new oil seals with ATF and install them to
the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
24 8RY 0 0027
22. Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod
as shown in the figure.
24 8RY 0 0005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 11 4 p s i )
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in) Inside Outside
Bearing
and race33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod

7A4–32 UNIT REPAIR (AW30–40LE)
If the values are nonstandard, check for an improper
installation.
24 8RY 0 000 4
23. Coat the race with petroleum jelly and install it onto
the overdrive support assembly.
Race diameter (Reference)
25 2RY 0 000 7
24. Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.
25 2RY 0 0005
25. Using snap ring pliers, install the snap ring as
shown in the figure.
25 2RY 0 0008
Inside Outside
Race 36.7 mm (1.44 in) 50.8 mm (2.00 in)

7A4–36 UNIT REPAIR (AW30–40LE)
34. Install the overdrive planetary gear and direct clutch.
2 52L10 000 1
35. Coat the assembled bearing and race with
petroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
2 52L10 001 8
36. Coat the race with petroleum jelly and install it onto
the oil pump.
Race diameter (Reference)
25 2RY 0 0014
37. Coat the O-ring with ATF and install it around the
pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CA UTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N·m (16 lb ft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.
24 1RY 0 0003
Inside Outside
Bearing
and race28.9 mm (1.138 in) 50.2 mm (1.976 in)
Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

7A4–88 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove assembled thrust bearing and race from
transmission case.
24 7RY 0 004 3
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.
24 6RY 0 001 6
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.
24 7RY 0 0002
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.
24 6RY 0 0016

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.
24 6RY 0 0018
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.
24 6RY 0 0019

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.
24 6RY 0 002 0
7. Place piston return spring onto first and reverse
brake piston No.2.
24 6RY 0 002 1
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.
24 7RY 0 0002
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.
24 6RY 0 0022