Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual — part 386
7A-92 AUTOMATIC TRANSMISSION (AW30-40LE)
DISASSEMBLY OF MAJOR
COMPONENTS (1)
240R200015
Disassembly steps
1. Torque converter
2. Neutral start switch
3. Oil temperature sensor
4. Elbow
5. Breather hose
6. Transmission select lever
7. Adapter housing (4
× 4)
8. Speedometer sensor, speedometer
driven gear and plate (4
× 2)
9. Extension housing (4
× 2)
10. Transmission assembly
AUTOMATIC TRANSMISSION (AW30-40LE) 7A-93
Disassembly steps
1. Torque converter
240R200016
2. Neutral start switch
Unstake the lock washer.
Remove the nut and bolts, and then remove the neutral
start switch.
Remove the lock washer and grommet.
3. Oil temperature sensor
240RY00001
4. Elbow
Remove two elbows from transmission case.
5. Breather hose
6. Transmission select lever
Remove the transmission select lever.
7. Adapter housing (4
×××× 4)
8. Speedometer sensor, speedometer driven gear and
plate (4
×××× 2)
9. Extension housing (4
×××× 2)
240R200021
10. Transmission assembly
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (J-37227)
Fixture base: 5-8840-0003-0 (J-3289-20)
7A-94 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR
COMPONENTS (1)
240R200020
Reassembly steps
1. Transmission
assembly
2. Extension
housing
(4×2)
3. Speedometer driven gear, plate, and
speedometer sensor (4×2)
4. Adapter housing (4×4)
5. Transmission
select
lever
6. Breather
hose
7. Elbow
8. Oil temperature sensor
9. Neutral
start
switch
10. Torque converter
Reassembly steps
1. Transmission assembly
2. Extension housing (4×
×
×
×2)
Install a new gasket and the extension housing to the
transmission case.
Torque: 36 N・・・・m (3.7 kg・・・・m/27 Ib・・・・ft)
AUTOMATIC TRANSMISSION (AW30-40LE) 7A-95
3. Speedometer driven gear, plate, and speedometer
sensor (4×
×
×
×2)
Torque:
Plate bolt – 15 N・・・・m (1.5 kg・・・・m/11 Ib・・・・ft)
Speedometer sensor – 25 N・・・・m (2.5 kg・・・・m/18 Ib・・・・ft)
241RY00020
4. Adapter housing (4×
×
×
×4)
Remove any gasket material on the contacting surfaces
of the adapter housing and transmission case.
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 (3.5 kg・・・・m/25 Ib・・・・ft)
5. Transmission select lever
Install transmission select lever.
Torque: 16 N・・・・m (1.6 kg・・・・m/12 Ib・・・・ft)
6. Breather hose.
240R200017
7. 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 (3.0 kg・・・・m/22 Ib・・・・ft)
240R200026
8. Oil temperature sensor
Install the oil temperature sensor to the transmission
case.
Torque: 30 N・・・・m (3.1 kg・・・・m/22 Ib・・・・ft)
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