Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1912

7A4-80 UNIT REPAIR (JR405E)

249L300005

•

Apply sealing agent (TB1216B) to the rear extension

(2WD) or adapter case (4WD) contact surfaces.

249L300006

•

Install the rear extension (2WD) or adapter case (4WD)

to the transmission case and tighten the 10 bolts to the

specified torque.

Torque: 53 N

⋅⋅⋅⋅

m (39 Ib

⋅⋅⋅⋅

ft)

43ASSY119

20.Control valve assembly

•

Align the manual valve and the manual plate of the

transmission case.

•

Install the control valve assembly and tighten the 12

fixing bolts to the specified torque.

Number of bolts

Length

Color

10 (A)

40 mm (1.57 in)

Gold

2 (B)

30 mm (1.18 in)

Gold

44ASSY121

Torque: 8 N

⋅⋅⋅⋅

m (69 Ib

⋅⋅⋅⋅

in)

UNIT REPAIR (JR405E) 7A4-81

45CV29

•

Connect the harness assembly and control valve

assembly connectors.

244L300001

21.Oil pan

•

Install a new gasket and the oil pan.

•

Tighten the bolts to the specified torque.

Torque: 8 N

⋅⋅⋅⋅

m (69 Ib

⋅⋅⋅⋅

in)

7A4-82 UNIT REPAIR (JR405E)

47INH-SW01

22.Inhibitor switch

•

Secure the inhibitor switch (1) by hand-tightening the 2

bolts.

•

Use the inhibitor switch set plate to align the neutral

holes (manual shaft and inhibitor switch).

Turn the inhibitor switch to adjust it.

Inhibitor switch set plate: 5-8840-2763-0

NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.

•

Tighten the 2 inhibitor switch bolts to the specified

torque.

Torque: 5.5 N

⋅⋅⋅⋅

m (48 Ib

⋅⋅⋅⋅

in)

•

Remove the holding fixture from the transmission case.

240L300001

23.Speed sensor and turbine sensor

•

Apply ATF to the new O-rings and install them the

speed sensor (2) and the turbine sensor (3).

•

Install the speed sensor and the turbine sensor. Tighten

the bolt to the specified torque.

Torque: 6 N

⋅⋅⋅⋅

m (52 Ib

⋅⋅⋅⋅

in)

24.Torque converter

•

Pour the new ATF into the torque converter.

•

Shake the torque converter to thoroughly clean the

inside.

•

Drain the ATF from the torque converter.

•

Pour the new ATF into the torque converter.

NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.

A07L300003

•

Install the torque converter.

•

Measure the torque converter end play (A).

If the measured value is greater than the specified

minimum, the torque converter is correctly installed.

Torque converter end pay (Minimum): 67 mm (2.64

in)

UNIT REPAIR (JR405E) 7A4-83

SERVICE STANDARD

Name

ATF DEXRON

Ⅲ

ATF

Quantity L

9.2

– 9.6

Seal ring clearance

mm (in) 0.10 – 0.25 (0.0039 – 0.0098)

Housing and inner rotor side clearance

mm (in) 0.02 – 0.04 (0.0008 – 0.0016)

Oil pump

Outer rotor and crescent clearance

mm (in) 0.02 – 0.15 (0.0008 – 0.0059)

Number of drive plate / driven plate

7/7

Standard mm

(in)

2.0

(0.079)

Drive plate facing thickness

Limit mm

(in)

1.8

(0.071)

Retaining plate and snap ring clearance

mm (in)

0.9 – 1.3

(0.035 – 0.051)

3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)

Available low clutch retaining plate thickness

mm (in)

4.8 (0.189)

Number of coil

9.9

Outside diameter

mm (in)

9.7

(0.382)

Free length

mm (in)

36.4

(1.433)

Low clutch

Return spring

Linear diameter

mm (in)

1.2

(0.047)

Number of drive plate / driven plate

5/5

Standard mm

(in)

2.0

(0.079)

Drive plate facing thickness

Limit mm

(in)

1.8

(0.071)

Retaining plate and snap ring clearance

mm (in)

1.2 – 1.6

(0.047 – 0.063)

4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)

Available high clutch retaining plate thickness

mm (in)

5.4 (0.213)

Number of coil

10.2

Outside diameter

mm (in)

8.0

(0.315)

Free length

mm (in)

27.1

(1.067)

High clutch

Return spring

Linear diameter

mm (in)

1.1

(0.043)

Number of drive plate / driven plate

2/2

Standard mm

(in)

2.0

(0.079)

Drive plate facing thickness

Limit mm

(in)

1.8

(0.071)

Retaining plate and snap ring clearance

mm (in)

0.6 – 0.9

(0.0236 – 0.035)

4.8 (0.189)
5.0 (0.197)
5.2 (0.205)

Reverse clutch

Available reverse clutch retaining plate thickness

mm (in)

5.4 (0.213)

Low one-way
clutch

Seal ring clearance

mm (in) 0.10 – 0.25 (0.0039 – 0.0098)

Number of drive plate / driven plate

6/6

Standard mm

(in)

2.0

(0.079)

Drive plate facing thickness

Limit mm

(in)

1.8

(0.071)

Retaining plate and snap ring clearance

mm (in)

0.7 – 1.1

(0.028 – 0.043)

5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)

Low & reverse
brake

Available low & reverse brake retaining plate
thickness

mm (in)

6.0 (0.236)