2004 ISUZU TF SERIES clutch

7A4-38 UNIT REPAIR (JR405E)

21R&H21

10.Dish plate, drive plates, driven plates, and retaining
plate Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).

248L300003

11.Snap ring
Install the snap ring.

NOTE:
If is careful in the attachment direction of dish plate (1).

22R&H35



Install the reverse and high clutch drum to the oil pump
assembly.

Force compressed air (392 kPa/4.0 kg/cm
2) through the
oil pump oil passages to check high clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


23CLEAR02



Measure the clearance between the high clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)

UNIT REPAIR (JR405E) 7A4-39
248L300004

5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)




24R&H34


Force compressed air (392 kPa/4.0 kg/cm2) through the
oil pump oil passages to check reverse clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.

7A4-40 UNIT REPAIR (JR405E)

25CLEAR04



Measure the clearance between the reverse clutch
retaining plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Reverse clutch retaining plate and snap ring
clearance (B):
0.6~0.9 mm (0.024~0.035 in)
Available reverse clutch retaining plate thicknesses
4.8 mm (0.189 in)
5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)

UNIT REPAIR (JR405E) 7A4-41

CARRIER AND LOW CLUTCH
ASSEMBLY

01C&L12
Legend
1. Snap ring
2. Front carrier
3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10. Bearing race
11. Snap ring
12. Retaining plate
13. Drive plates (7, low clutch)
14. Driven plates (6, low clutch)


15. Driven plate (1, 2 mm thick, low clutch)
16. Dish plate
17. Snap ring
18. Cancel cover
19. Return spring
20. Low clutch piston
21. Seal ring (small)
22. Seal ring (large)
23. Low clutch drum
24. Bearing
25. Snap ring
26. Low one-way clutch
27. Side plate
28. Snap ring

7A4-42 UNIT REPAIR (JR405E)

02C&L-SUB03

Disassembly steps
1. Snap ring
Remove the snap ring from the low clutch drum.


03C&L-SUB05

2. Front carrier
Remove the front carrier from the low clutch assembly.


04C&L-SUB06

3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10.Bearing race Remove the bearing (with bearing race), the rear sun gear,
the bearing, the rear carrier, the bearing race, the bearing,
and rear internal gear.

05C&L-SUB07

7A4-44 UNIT REPAIR (JR405E)

11C&L-SUB13

11.Snap ring
Remove the low clutch snap ring.


12C&L-SUB15

12.Retaining plate, drive plate, driven plate, and dish plate
Remove the low clutch retaining plate, the 7 drive plates,
the 7 driven plates, and the dish plate.

13C&L-SUB18

13.Snap ring

Install the spring compressor to the low clutch drum.
Spring compressor: 5-8840-2759-0

Carefully press the cancel cover down.
Take care not to damage the return spring.


14C&L-SUB19



Remove the snap ring.


31C&L-SUB20

14.Cancel cover
Remove the cancel cover.

UNIT REPAIR (JR405E) 7A4-45

30C&L-SUB21

15.Return spring
Remove the return spring.


15C&L-SUB38

16.Low clutch piston

Insert the low one-way clutch inner race to the low clutch
drum.

Force compressed air through the oil passages of the
low one-way clutch inner race to remove the low clutch
piston.


29C&L-SUB22



16C&L-SUB25

17.Snap ring

Raise the low one-way clutch side.

Remove the low one-way clutch snap ring.


17C&L-SUB27

18.Side plate
Remove the side plate.

7A4-46 UNIT REPAIR (JR405E)

18C&L-SUB28

19.Low one-way clutch
Remove the low one-way clutch.

19C&L-SUB29

20.Snap ring
Remove the snap ring from the low clutch drum.

20C&L-SUB31

21.Bearing
Remove the bearing.



Inspection
Drive plate

Measure the drive plate facing thickness at 3 points.

Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)
Return spring

Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 9.9

Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 9.7 mm (0.382 in)