2004 ISUZU TF SERIES clock

7A4–74 UNIT REPAIR (AW30–40LE)
Disassembly
1. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
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2. Remove the one-way clutch and second brake hub.
3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).
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5. Remove the snap ring with snap ring pliers.
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6. Remove the sun gear input drum.
7. Remove the snap ring from planetary sun gear.
Inspection and Repair
1. Check planetary sun gear bushing
Using a dial indicator, measure the inside diameter
of the planetary sun gear bushing.
Maximum inside diameter: 27.08 mm (1.066 in)
If the inside diameter is greater than the maximum,
replace the planetary sun gear.
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Legend
(1) Free
(2) Lock

7A4–76 UNIT REPAIR (AW30–40LE)
5. Install thrust washer (plastic).
NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
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6. Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
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7. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
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Legend
(1) Free
(2) Lock

7A4–82 UNIT REPAIR (AW30–40LE)
Disassembly
1. Remove second brake assembly from output shaft.
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2. Remove oil seal ring from output shaft.
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3. Remove the seven discs, seven plates and flange
(B–3).4. Remove rear planetary gear from rear planetary ring
gear.
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5. Check operation of No.2 one-way clutch.
Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
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Legend
(1) Lock
(2) Free

UNIT REPAIR (AW30–40LE) 7A4–85
7. While turning counterclockwise, install one-way
clutch inner race to rear planetary gear.
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8. Check operation of one-way clutch.
Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
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9. Install rear planetary gear onto rear planetary ring
gear.
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10. Install the disc, plate and flange (B–3).
Install a brake flange onto the rear planetary gear
assembly.
Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
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Legend
(1) Lock
(2) Free

7A4–124 UNIT REPAIR (AW30–40LE)
Torque Converter
Inspection and Repair
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : J–35467
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.
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1. One-way clutch test.
The clutch should lock when turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5 N·cm (22 Ib in) of torque
should be required to rotate the clutch clockwise. If
necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.

CONSTRUCTION AND FUNCTION 7A1-13

2-4 Brake and Low & Reverse Brake (Multi-Plate Brake)

The multi-plate brake is composed of drive plates and driven plates. By applying the oil pressure onto
the end surface of the plates, the clutch is engaged or disengaged. The oil pressure is adjusted with the
control valve according to the signal from the TCM.

All brakes use dish plates to prevent uncontrolled operation of the clutches when engaged, causing a
shock.

The solenoid in the control valve is driven based on the speed change signal from TCM and moves the
shift valve, thereby engaging the drive plate and driven plate through the piston of each clutch.

Resultantly, rotation of each element of the planetary gear unit is fixed.

When the oil pressure is removed, the piston returns to the original position by the force of the return
spring.




Figure 19. Construction of 2-4 Brake
Figure 20. Construction of Low & Reverse Brake

Low One-way Clutch

The low one-way clutch employs the sprag which locks the counterclockwise rotation of the front planetary
carrier and rear internal gear.

The one-way clutch outer race is fitted with the low clutch drum and the inner race with the transmission
case.

The outer race rotates freely clockwise but, when it attempts to rotate counterclockwise, the sprag
functions to lock the outer race.

When the vehicle is traveling in 1st gear in the D, 3 or 2range, the low one-way clutch locks the rear
internal gear via the low clutch. It is left free in the 2nd, 3rd or 4th gear position.


Figure 21. Construction of Low One-way Clutch

7A1-36 CONSTRUCTION AND FUNCTION
GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION AND
HYDRAULIC CIRCUIT
CONSTRUCTION AND OPERATION
The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate brakes
and one one-way clutch.





COMPONENT NAME AND FUNCTION
Component Name Symbol Function
Low Clutch L/C Connects the front planetary carrier to the rear
internal gear.
Engaged at 1st, 2nd and 3rd gear.
High Clutch H/C Connects the input shaft to the front planetary
carrier.
Engaged at 3rd and 4th (O/D) gear.
Reverse Clutch R/C Connects the input shaft to the front sun gear.
Engaged at Reverse gear.
Low & Reverse Brake L&R/B Locks the front planetary carrier.
Engaged at L range and Reverse gear.
2-4 Brake 2-4/B Locks the front sun gear.
Engaged at 2nd and 4th (O/D) gear.
Low One-way Clutch L/O.C Allows the front planetary carrier to turn forward
(clockwise) but locks to opposite direction
(counterclockwise).
Operative when accelerating.
Low Clutch Solenoid L/C.S Regulates low clutch pressure.
High Clutch Solenoid H/C.S Regulates high clutch pressure.
Low & Reverse Brake Solenoid L&R/B.S Regulates low & reverse brake pressure.
2-4 Brake Solenoid 2-4/B.S Regulates 2-4 brake pressure.
Lock-up Solenoid L/U.S Regulates lock-up clutch pressure.
High Clutch Oil Pressure SW H/C.P/SW Detects high clutch supply oil pressure.
Low & Reverse Brake Oil Pressure SW L&R/B.P/SWDetects low & reverse brake supply oil pressure.
2-4 Brake Oil Pressure SW 2-4/B.P/SWDetects 2-4 brake supply oil pressure.

7A1-40 CONSTRUCTION AND FUNCTION
Reverse Gear in Range
The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. In the R
range, the reverse clutch is engaged and the driving force is transmitted to the front sun gear and rotates it
clockwise. The low & reverse brake is also engaged and the front planetary carrier is fixed so that the front pinion
gear does not rotate clockwise but can rotate counterclockwise. As a result, the output shaft rotates
counterclockwise and the vehicle goes back.