2004 ISUZU TF SERIES length

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

7A4–20 UNIT REPAIR (AW30–40LE)
Install two removed bolts to the OD support, and
pull out the OD support assembly.
25 2RY 0 000 5
12. Remove the race from OD support.
25 2RY 0 000 6
13. Check piston stroke of second coast brake (B–1)
Place a mark on the second coast brake piston rod
as shown in the figure.
Using feeler gauge, measure the stroke applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band.There are two piston rods.
24 8RY 0 0004
24 8RY 0 0005
Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)

UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 002 7
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
25 2RY 0 002 8
3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
25 2RY 0 0029
4. Check OD direct clutch drum bushings.
Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in)
If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
25 2L10 0009

7A4–54 UNIT REPAIR (AW30–40LE)
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
25 2RY 0 004 3
2. Remove the thrust bearing.
3. Remove the race.
4. Remove the thrust washer (plastic).
5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Remove the snap ring with a screwdriver.
RUW 37A SH00 310 1
6. Romove the piston return spring.7. Place the OD support onto the direct clutch
assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
25 2RY 0 0045
8. Remove the O-ring and oil seal rings from OD
support.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 17.2 mm (0.677 in)
25 2RY 0 0046

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
24 8RY 0 003 0
8. Remove two O-rings from piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)
24 7RY 0 003 4
2. Check discs.
Using micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 0027
3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031

UNIT REPAIR (AW30–40LE) 7A4–67
Before assembling new discs, soak them in ATF
for at least fifteen minutes.
24 8RY 0 004 5
4. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 19.47 mm (0.7665 in)
24 7RY 0 003 4
Reassembly
1. Coat the assembled thrust bearing and race with
petroleum jelly and install it onto the forward clutch
drum, with the race side facing downward.
Bearing and race (Reference)
24 8RY 0 0044
2. Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install
three oil seal rings onto the forward clutch drum.
NOTE: Do not spread the ring ends more than
necessary.
24 8RY 0 0046
Inside diameter 33.7 mm (1.327 in)
Outside diameter 47.8 mm (1.882 in)

7A4–78 UNIT REPAIR (AW30–40LE)
2. Remove the hrust washer (plastic).
3. Place 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 0 000 1
4. Remove the spring retainer and piston return spring.
5. Romove piston sleeve.
6. Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
24 6RY 0 000 8
7. Remove the o-rings from the second brake piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 18.38 mm (0.724 in)
24 7RY 0 0034
Reassembly
1. Coat new O-rings with ATF and install them on the
second brake piston.
24 6RY 0 0009
2. Being careful not to damage the O-rings, press in
the second brake piston into the second brake
drum.
3. Install piston sleeve.

7A4–94 UNIT REPAIR (AW30–40LE)
4. Place upper valve body with plate and gaskets on
top of lower valve body.
Align each bolt hole and gasket in the valve body.
2 44R20 007 4
5. Install the pressure control solenoid and clamp.
6. Install thirty bolts to upper valve body.
Each bolt is indicated in the figure.
Torque: 6.4 N·m (57Ibin)
2 44R20 0050
7. Install manual shift valve.
Length (mm) Quantity
A207
B2812
C4011