Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 401

7A-152 AUTOMATIC TRANSMISSION (AW30-40LE)

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Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support
assembly.

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Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (390 –
780 kPa, 4 – 8 kg/cm

2

or 57 – 114 psi) as shown.

Piston stroke: 1.37 – 1.60 mm (0.0539 – 0.0630 in)

1. Clutch drum thrust washer (Plastic)
2. Snap ring
3. Flange
4. Plate and disc

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5. Snap ring

Place special tool on the spring retainer and compress
the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : 5-8840-0254-0 (J-25048)

6. Piston return spring

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7. Direct clutch drum
8. Direct clutch piston
9. O-ring

Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the direct
clutch piston.
Remove the direct clutch piston.
Remove two O-rings from piston.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-153

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INSPECTON AND REPAIR

Check piston return spring

Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)

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Check discs

Using micrometer, measure the thickness of the discs.
Minimum thickness: 2.04±

±

±

±0.05 mm

(0.0803±

±

±

±0.0020 in)

If the thickness is less than the minimum, replace the
disc.

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Check direct 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.

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Check direct clutch drum bushing

Using a dial indicator, measure the inside diameter of
the clutch drum bushing.
Maximum inside diameter: 53.93 mm (2.1232 in)
If the inside diamater is greater than the maximum,
replace the clutch drum.

7A-154 AUTOMATIC TRANSMISSION (AW30-40LE)

REASSEMBLY

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Reassembly steps

1. O-ring
2. Direct clutch piston
3. Direct clutch drum
4. Piston

return

spring

5. Snap

ring

6. Disc and plate
7. Flange
8. Snap

ring

9. Clutch drum thrust washer (Plastic)

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Reassembly steps

1. O-ring
2. Direct clutch piston
3. Direct clutch drum

Coat new O-rings with ATF and install them on the
direct clutch piston.
Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the
direct clutch piston into the clutch drum, using both
hands.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-155

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4. Piston return spring

Install piston return spring.

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5. Snap ring

Compress piston return spring and install snap ring in
groove.
Place special tool on the spring retainer, and compress
the return spring.
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.
Spring compressor: 5-8840-0254-0 (J-25048)

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6. Disc and plate

Install plates and discs.
Install in order : P-D-P-D-P-D-P-D-P-D
P : Plate, D : Disc

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7. Flange

Install the flange, with the flat side facing downward.

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8. Snap ring

Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned with
the cutout portion of the direct clutch drum.