2004 ISUZU TF SERIES oil

UNIT REPAIR (AW30–40LE) 7A4–51
13. Install two plates and two discs then install the
flange, with the flat side facing downward.
2 52L10 001 3
14. Install snap ring.
2 52L10 001 4
15. Check piston stroke of OD direct clutch (C–0)
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
25 2L10 0005Using a dial indicator, measure the OD direct clutch
piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
25 2L10 0016
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)

UNIT REPAIR (AW30–40LE) 7A4–53
OD Support Assembly
Disassembled View
2 52R20 0003
E nd O FCallo ut
Disassembly
1. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.
25 2RY 0 0042
Legend
(1) Thrust bearing
(2) Race
(3) Thrust washer (plastic)
(4) Snap ring(5) Piston return spring
(6) OD brake piston
(7) O-ring
(8) Oil seal ring
(9) OD support

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

UNIT REPAIR (AW30–40LE) 7A4–55
Reassembly
1. Coat the two oil seal rings with ATF.
Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.
25 2RY 0 004 7
2. Coat two new O-rings with ATF and install them on
the OD brake piston.
3. Being careful not to damage the O-rings, press the
brake piston into the OD support, using both hands.
25 2RY 0 004 8
4. Install piston return spring.
25 2RY 0 0049
5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
with cutout portion of the OD support.
RUW3 7A SH00 3201

UNIT REPAIR (AW30–40LE) 7A4–57
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
25 2RY 0 004 3

7A4–64 UNIT REPAIR (AW30–40LE)
Forward Clutch Asseembly (C-1)
Disassembled View
2 48R20 0003
E nd O FCallo ut
Legend
(1) Thrust bearing
(2) Race
(3) Snap ring
(4) Flange
(5) Disc and plate
Six discs and six plates
(6) Cushion plate(7) Snap ring
(8) Piston return spring
(9) Piston
(10) O-ring
(11) O-ring
(12 Oil seal ring
(13) Thrust bearing
(14) Forward clutch drum

7A4–66 UNIT REPAIR (AW30–40LE)
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048
24 8RY 0 000 3
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
24 8RY 0 004 2
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from
forward clutch drum.
Inspection and Repair
1. Check forward 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
2. Check forward clutch drum bushing.
Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 in)
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
24 8RY 0 0043
3. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.

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)