Isuzu Trooper (1998-2002 year). Service manual — part 737
AUTOMATIC TRANSMISSION (AW30-40LE)
7A–145
REASSEMBLY
248RY00064
Reassembly steps
▲
1. Thrust bearing
▲
2. Oil seal ring
▲
3. O-ring
▲
4. O-ring
▲
5. Forward clutch piston
▲
6. Piston return spring
▲
7. Snap ring
▲
8. Cushion plate
▲
9. Disc and plate
▲
10. Flange
▲
11. Snap ring
▲
12. Race
▲
13. Thrust bearing
7A–146
AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00044
248RY00046
248RY00047
248RY00049
Important operations
1. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch drum, with the race
side facing downward.
2. Oil seal ring
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.
3. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
4. O-ring
Coat new O-rings with ATF and install two O-rings on the
forward clutch piston.
5. Forward clutch piston
Being careful not to damage the O-rings, press the forward
clutch piston into the forward clutch drum.
Assembled bearing and race (Reference) mm (in.)
Inside diameter
33.7 (1.327)
Outside diameter
47.8 (1.882)
AUTOMATIC TRANSMISSION (AW30-40LE)
7A–147
248RY00065
248RY00003
248RY00069
248RY00070
6. Piston return spring
Install piston return spring.
7. Snap ring
Place special tool on the spring retainer, and compress the
return spring.
Spring compressor: 5–8840–0254–0 (J–25048)
Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
8. Cushion plate
Install cushion plate rounded side down as shown.
9. Disc and plate
Install discs. plates and flange.
Install in order:P–D–P–D–P–D–P–D–P–D–P–D
10. Flange
And then install the flange, with the rounded edge facing
downward.
7A–148
AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00041
248RY00040
248RY00048
11. Snap ring
Install the snap ring with a screw driver. Be sure the end
gap of the snap ring is not aligned with the cutout portion of
the forward clutch drum.
Check piston stroke of forward clutch (C–1)
Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing the compressed air (4–
8kg/cm
2
, 57–114psi or 392–785kPa) as shown.
If the Pack clearance is not within specification, select
another flange, and recheck the piston stroke.
There are eight flanges.
12. Race
13. Thrust bearing
Coat the race and bearing with petroleum jelly, and install
them onto the forward clutch drum.
mm(in.)
Pack clearance
0.6–1.0
(0.0236–0.0394)
mm (in.)
No.
Flange thickness
No.
Flange thickness
61
3.0 (0.118)
92
3.4 (0.134)
63
4.2 (0.165)
93
3.6 (0.142)
64
4.4 (0.173)
94
3.8 (0.150)
91
3.2 (0.126)
95
4.0 (0.158)
Race and bearing diameter (Reference)
mm(in.)
Inside
Outside
Race
26.0 (1.024)
48.9 (1.925)
Bearing
26.0 (1.024)
46.7 (1.839)
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