2004 ISUZU TF SERIES brake

UNIT REPAIR (JR405E) 7A4-63

39L&R04


249L300003



Measure the clearance between the low and reverse
retaining plate and the snap ring.
If the clearance is out side the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Low and reverse retaining and snap ring clearance:
0.7~1.1 mm (0.028~0.043 in)
Available low and reverse brake retaining plate
thickensses
5.2 mm (0.205 in)
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)

10.Dish plate, drive plate, driven plate, and retaining plate
(2-4 brake)
NOTE:
It is careful in the attachment direction of dish plate (1).
If 2-4 brake clearance measurement is required, it must be
done now.
Brake clearance cannot be measured after the carrier
assembly has been installed.

402-4B08



Install the 2-4 brake dish plate to the transmission case
(plate contact surface).

7A4-64 UNIT REPAIR (JR405E)

412-4B09



Install the drive plate, driven plate, and the retaining
plate.


422-4B10



432-4B11



442-4B12

11.2
– 4 brake piston and 2 – 4 brake retainer

Install new seal ring to the 2-4 brake piston.

Install the 2-4 brake piston to the 2-4 brake retainer.


452-4B15



Install the 2-4 brake piston and the 2-4 brake retainer to
the transmission case.
Pay close attention to the retainer projection from the
case groove.

UNIT REPAIR (JR405E) 7A4-65

472-4B17



Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Be sure that the spring compressor is perfectly centered
(an off-center special tool will damage the return spring).

Use the spring compressor to force the 2-4 brake
retainer.


482-4B18

NOTE:
To avoid damaging the return spring, apply as little force
as possible to the 2-4 brake retainer.

Install the snap ring.


492-4B22



Force compressed air (392 kPa/4.0 kg/cm2) through the
oil passages of the transmission case to operate and
break-in the 2-4 brake.


502-4B19



Measure the clearance between the 2-4 brake retainer
and the retaining plate.
If the clearance is outside the specified range, replace
the existing brake retainer with a new one of the prope
r
size (thickness).
2 – 4 brake retainer and retaining plate clearance:
1.0~1.4 mm (0.039~0.055 in)
Available 2-4 brake retaining plate thicknesses
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
6.2 mm (0.244 in)
6.4 mm (0.252 in)

Use the spring compressor to release the 2-4 brake.

7A4-72 UNIT REPAIR (JR405E)

03ASSY013

3. Carrier and low clutch assembly
Install the carrier and low clutch assembly to the
transmission case.
NOTE:
Do not allow the low clutch drum end to protrude beyond
the 2-4 brake plate contact surface (transmission case).


04ASSY014

4. Bearing
Install the bearing to the carrier and low clutch assembly.


05ASSY015

5. Driven plate, drive plate, retaining plate, and dish plate
(2 – 4 brake)
Install the 2-4 brake 5 driven plate (1), 5 drive plates (2),
retaining plate (3), and dish plate (4) in that order.
NOTE:







The thickest driven plate (5.6 mm) must be installed
at the bottom (transmission case plate surface).







Dish plate side with the identification mark must
face the retaining plate.


06ASSY016



07ASSY017

UNIT REPAIR (JR405E) 7A4-73

08ASSY018






RTW47ASH000401



09U-SPG2

6. 2
– 4 brake spring
Install the 2-4 brake springs (3) to the transmission case.





248L300009

7A4-74 UNIT REPAIR (JR405E)

10ASSY019

7. Return spring and 2
– 4 brake retainer

Align the transmission case groove and the 2-4 brake
retainer projection.

Install the return spring and the 2-4 brake retainer.

11ASSY028



12ASSY029

Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Carefully center the spring compressor to prevent damage
to the return spring.

Push the 2-4 brake retainer into place.
NOTE:
Do not push the brake retainer too far.
Damage to the return spring will result.

Install the snap ring.


14ASSY031



17ASSY113

8. Sleeve and seal ring

Install the new sleeve and seal ring to the transmission
case.

UNIT REPAIR (JR405E) 7A4-75

192-4B22



Force compressed air (392 kPa/4.0 kg/cm2) through the
transmission case oil passage to 2-4 brake operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing

Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040

Install the front sun gear to the transmission case.


22ASSY042

Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.

7A4-84 UNIT REPAIR (JR405E)

SERVICE STANDARD
Name BESCO ATF II or ATF III ATF
Quantity L 9.2 – 9.6
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plate / driven plate 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coil 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring
Linear diameter mm (in) 1.2 (0.047)
Number of drive plate / driven plate 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coil 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drive plate / driven plate 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.0236 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in)
5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plate / driven plate 6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)