Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1792

UNIT REPAIR (JR405E) 7A4-35

08R&H36

8. High clutch piston

9. Reverse clutch piston

•

Install the reverse and high clutch drum to the oil pump.

•

Force compressed air into the oil pump oil channels.

•

Remove the high clutch piston and the reverse clutch

piston.

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12R&H39

10.Seal ring (high clutch)

Remove the 2 seal rings from the high clutch piston.

13R&H38

11.Seal ring (reverse clutch)

Remove the 2 seal rings from the reverse clutch piston.

Inspection

Drive plate

•

Measure the drive plate facing thickness at 3 points.

•

Calculate the average value.

If the average value is less than the specified limit, the

drive plate must be replaced.

Drive plate facing thickness:

Standard – 2.0 mm (0.079 in)

Limit – 1.8 mm (0.071 in)

7A4-36 UNIT REPAIR (JR405E)

Return spring

•

Check the number of effective return spring coils.

If the number is less than the specified minimum, the

return spring must be replaced.
Effective return spring coils (standard): 10.2

•

Measure the return spring outside diameter, free length,

and linear diameter.

If any of the measured values exceed the specified limit,

the return spring must be replaced.

Return spring measurements (standard):

Outside diameter – 8.0 mm (0.315 in)

Free length – 27.1 mm (1.067 in)

Linear diameter – 1.1 mm (0.043 in)

10R&H40

Reverse clutch piston

•

Apply compressed air (392 kPa/4.0 kg/cm

2

) to the

reverse clutch piston from the outside to the inside.

The flow of air should be blocked.

11R&H44

•

Apply compressed air (392 kPa/4.0 kg/cm

2

) to the

reverse clutch piston from inside to the outside.

The flow of air should be unrestricted.

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Reassembly steps

Coat the parts with ATF before installing them.
1. Seal ring (high clutch)

Install new seal rings to the high clutch piston.

UNIT REPAIR (JR405E) 7A4-37

13R&H38

2. Seal ring (reverse clutch)

Install new seal rings to the reverse clutch piston.

14R&H32

3. Reverse clutch piston

Install the reverse clutch piston to the reverse and high

clutch drum.

15R&H31

4. High clutch piston

Install the high clutch piston to the reverse clutch piston.

16R&H33

5. Return spring

Install the return spring to the high clutch piston.

17R&H30

6. High clutch cover

•

Carefully center the high clutch cover and install it.

NOTE:
If the clutch cover is not centered, the cover outside seal
gum will be forced into the piston area where it will be
damaged.

7A4-38 UNIT REPAIR (JR405E)

18R&H27

7. Snap ring

•

Install the spring compressor to the reverse and high

clutch drum.

•

Use the spring compressor to carefully force the high

clutch cover down.

Spring compressor: 5-8840-2767-0

NOTE:
To avoid damage to return springs, use only as much
force as is required to press the high clutch cover into
place.

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•

Install the new snap ring to the reverse and high clutch

drum.

20R&H25

8. Dish plate, drive plates, driven plates, and retaining

plate

Install the high clutch dish plate (1), the 5 driven plates (2),

the 5 drive plates (3), and retaining plate (4).

248L300002

9. Snap ring

Install the snap ring.