2004 ISUZU TF SERIES torque

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-47

3. Install the protector and fuel pipe bracket.

Install the bracket with the fuel pipes (3) to the
transmission.
 Install the protector (2) and tighten nuts (1).



RTW37ASH001201
4. Connect the air bleezer hose on the transmission.
5. Install the transmission crossmember.
Torque: 67 N 


m (6.8 kg 


m/49 lb ft)
6. Install the heat protector and the fuel pipe clips with
fuel pipes on the transmission crossmember.





P1010005B
7. Install rear mount nuts.
Torque: 50 N 


m (5.3 kg



m/37 lb ft)
8. Remove a transmission jack.

9. Install flex plate torque converter bolts.

Align the flex plate torque converter bolt boss
with flex plate hole by turning the torque
converter.
 Install flex plate torque converter bolts (6 pieces)
by turning the crankshaft.
Torque: 54 N 


m (54 kg



m/40 lb ft)
NOTE: Do not reuse the flex plate torque converte
r
bolt.





P1010005
10.Install the under covers to the transmission and
engine.
Torque: 8 N 


m (0.8 kg



m/69 lb in)





P1010012

7A3-48 ON-VEHICLE SERVICE (AW30 –40LE)

11. Install the suspension crossmember.
Torque: 65 N 


m (6.6 kg 


m/48 lb ft)
12. Install filler tube and insert oil level gage.
Torque: 22 N 


m (2.2 kg 


m/16 lb ft)
13. Install select cable by connecting inner cable to
select lever and installing outer cable with bracket.
14. Install the fuel pipe brackets to the transmission. Install the fuel pipe clips with the pipes to the
bracket.





P1010010
15. Connect the transmission harness connectors and
clips.
16. Connect transmission oil cooler pipes to A/T.
Torque: 44 N 


m (4.5 kg



m/33 lb ft)
17. Install oil cooler pipe clamp and bracket to the
converter housing.


18.Tighten oil cooler pipe clamp bolt at the engine
mount side.




P1010024
19. Install the transfer case assembly.(4WD only)

Apply a thin coat of molybdenum disulfide grease
to the input shaft spline as shown in the figure.


260R300001

Install the transfer case assembly.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-49


Tighten transmission transfer bolts as shown in
the figure.(4WD only)

261R300002
20. Connect transfer harness connectors and
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
21. Install the middle exhaust pipe.



RTW37ASH0001
22. Install the rear propeller shaft.
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.
23. Install the center bearing on crossmember.
Torque: 69 N 


m (7.0 kg 


m/51 lb ft)


24.Install the front propeller shaft.(4WD only)
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.


401RS023
25. Connect battery ground cable.

UNIT REPAIR (AW30–40LE) 7A4–1
TRANSMISSION
CONTENTS
UNIT REPAIR (AW30–40LE)
Major Components (1) ................................... 7A4–3
Major Components (1) and Associated
parts ........................................................... 7A4–3
Disassembly steps...................................... 7A4–3
Components (1) ............................................. 7A4–5
Reassembly ................................................ 7A4–5
Major Components (2) ................................... 7A4–7
Major Componets (2) and Associated
Parts ........................................................... 7A4–7
Disassembly ............................................... 7A4–8
Reassembly ................................................ 7A4–11
Major Components (3) ................................... 7A4–16
Major Components (3) and Associated
Parts ........................................................... 7A4–16
Disassembly ............................................... 7A4–17
Reassembly ................................................ 7A4–25
Diaassembly, Inspection and Reassembly
of minor Components ................................. 7A4–37
Oil Pump ........................................................ 7A4–38
Disassembly View ...................................... 7A4–38
Disassembly ............................................... 7A4–38
Inspection and Repair................................. 7A4–39
Reassembly ................................................ 7A4–41
OD Planetary Gear and OD Direct Clutch
Assembly (C–0).......................................... 7A4–43
Disassembled View .................................... 7A4–43
Disassembly ............................................... 7A4–44
Inspection and Repair................................. 7A4–47
Reassembly ................................................ 7A4–48
OD Support Assembly ................................... 7A4–53
Disassembled View .................................... 7A4–53
Disassembly ............................................... 7A4–53
Inspection and Repair................................. 7A4–54
Reassembly ................................................ 7A4–55
Direct Clutch Assembly (C-2) ........................ 7A4–58
Disassembled View .................................... 7A4–58
Disassembly ............................................... 7A4–59
Inspection and Repair................................. 7A4–60
Reassembly ................................................ 7A4–61
Forward Clutch Asseembly (C-1)................... 7A4–64
Disassembled View .................................... 7A4–64
Disassembly ............................................... 7A4–65
Inspection and Repair................................. 7A4–66
Reassembly ................................................ 7A4–67
Front Planetary Gear ..................................... 7A4–71
Disassembled View .................................... 7A4–71
Disassembly ............................................... 7A4–71
Inspection and Repair................................. 7A4–71
Reassembly ................................................ 7A4–72Planetary Sun Gear and No.1 One-Way
Clutch ......................................................... 7A4–73
Disassembled View .................................... 7A4–73
Disassembly ............................................... 7A4–74
Inspection and Repair ................................. 7A4–74
Reassembly ................................................ 7A4–75
Second Brake Assembly (B–2)...................... 7A4–77
Disassembled View .................................... 7A4–77
Disassembly ............................................... 7A4–77
Inspection and Repair ................................. 7A4–78
Reassembly ................................................ 7A4–78
Rear Planetary Gear Assembly and Output
Shaft ........................................................... 7A4–81
Disassembled View .................................... 7A4–81
Disassembly ............................................... 7A4–82
Reassembly ................................................ 7A4–84
First and Reverse Brake (B–3) ...................... 7A4–87
Disassembled View .................................... 7A4–87
Disassembly ............................................... 7A4–88
Reassembly ................................................ 7A4–89
Transmission Valve Body assembly .............. 7A4–92
Disassembled View .................................... 7A4–92
Disassembly ............................................... 7A4–93
Reassembly ................................................ 7A4–93
Lower Valve Body .......................................... 7A4–96
Cross Section ............................................. 7A4–96
Disassembly ............................................... 7A4–98
Inspection and Repair ................................. 7A4–103
Reassembly ................................................ 7A4–104
Upper Valve Body .......................................... 7A4–109
Cross Section ............................................. 7A4–109
Disassembly ............................................... 7A4–111
Inspection and Repair ................................. 7A4–115
Reassembly ................................................ 7A4–116
Transmission Case ........................................ 7A4–121
Disassembled View .................................... 7A4–121
Disassembly ............................................... 7A4–121
Reassembly ................................................ 7A4–122
Torque Converter........................................... 7A4–124
Inspection and Repair ................................. 7A4–124
Adapter Housing (4
4)................................. 7A4–125
Disassembled View .................................... 7A4–125
Disassembly ............................................... 7A4–125
Reassembly ................................................ 7A4–125
Ex tension Housing (4
2) ............................. 7A4–126
Disassembled View .................................... 7A4–126
Disassembly ............................................... 7A4–126
Reassembly ................................................ 7A4–126
Main Data and Specifications ........................ 7A4–128

UNIT REPAIR (AW30–40LE) 7A4–3
Major Components (1)
Major Components (1) and Associated parts
RTW 37A M F00 0601
E nd O FCallo ut
Disassembly steps
1. Remove the torque converter.
2. Remov e the select lev er.
Legend
(1) Torque converter
(2) Select lever
(3) Neutral start switch (Mode switch)
(4) Elbow
(5) Oil temperature sensor
(6) Breather hose
(7) Input revolution sensor(8) Output revolution sensor (4
4)
(9) Output revolution sensor (4
2)
(10) Speedometer sensor, speedometer driven gear
and plate (4
2)
(11) Extension housing (4
2)
(12) Adapter housing (4
4)
(13) Transmission assembly

UNIT REPAIR (AW30–40LE) 7A4–5
Components (1)
Reassembly
1. Install a new gasket and the ex tension housing
(4
2) to the transmission case.
Torque: 36 N·m (27 Ib ft)
2. Install the speedometer driven gear, plate, and
speedometer sensor (4
2).
To r q u e :
Plate bolt – 15 N·m (11 Ib ft)
Speedometer sensor – 25 N·m (18 Ib ft)
3. Install the adapter housing (4
4).
Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
24 1RY 0 002 0
Apply liquid gasket (TB1281–B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
Install the adapter housing to the transmission
case.
Torque: 34 N·m (25 Ib ft)
4. Install the neutral start switch.
Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
Install the lock washer and nut.
Torque: 7 N·m (61 Ib in)Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (113 Ib in)
Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW1 7A SH01 3601
5. Install the oil temperature sensor to the transmission
case.
Torque: 15 N·m (11 Ib ft)
RUW3 7A SH00 4001

7A4–6 UNIT REPAIR (AW30–40LE)
6. Install the elbow.
Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29 N·m (3.0kg·m/22 Ib ft)
RTW 37BSH00 060 1
7. Install the select lever.
8. Install the output revolution sensor (4
2).
9. Install the output revolution sensor (4
4).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter.
Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5 mm (0.53 in)
24 0RY 0 000 5

UNIT REPAIR (AW30–40LE) 7A4–13
24 0RY 0 002 9
24 0RY 0 001 0
8. Install new check valve and spring.
24 0RY 0 001 6
9. Install the valve body.
Align the groove of the manual valve to the pin of
the lever.
24 0RY 0 0017
Install the twenty bolts.
NOTE: Each bolt length (mm) is indicated in the figure.
Torque: 10 N·m (87lbin)
2 44R20 0078