Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 394

7A-124 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00024

Using vernier calipers, measure the distance between
the sun gear input drum and direct clutch drum as
shown in the figure.
Height: 9.8 – 11.8 mm (0.386 – 0.465 in)
If the values are nonstandard, check for an improper
installation.

Coat the assembled bearing and race with petroleum
jelly and install it onto the forward clutch.

Assembled bearing and race diameter
(Reference)

Inside

Outside

Bearing

and race

33.7 mm (1.327 in) 47.8 mm (1.882 in)

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19. Second coast brake piston assembly

Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E-ring.

①: Second coast brake piston

②: Oil seal

③: Piston rod

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20. Snap ring

Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly
and piston cover to the transmission case.
Using snap ring pliers, install the snap ring.

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Check piston stroke of second coast brake

Place a mark on the second coast brake piston rod as
shown in the figure.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-125

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Using wire gauge, measure the stroke by applying the
compressed air (390 – 780 kPa, 4 – 8 kg/cm

2

or 57 –

114 psi) as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
If the values are nonstandard, check for an improper
installation.

21. Race

Coat the race with petroleum jelly and install it onto the
overdrive support assembly.

Race diameter (Reference)

Inside

Outside

Race

36.8 mm (1.449 in) 50.9 mm (2.004 in)

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22. OD support

Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the bolt
hole of the transmission case and insert.

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23. Snap ring

Using snap ring pliers, install the snap ring as shown in
the figure.

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Install and tighten the two bolts.
Torque: 25 N････m (2.6 kg････m/19 Ib････ft)

7A-126 AUTOMATIC TRANSMISSION (AW30-40LE)

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Check end of output shaft

Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)

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24. Flange, plate and disc

Install the (flat ring) 4.0 mm (0.157 in) thick flange with
the rounded edge side of the flange facing the disc.
Alternately install three discs and two plates. (Disc first)

25. Snap ring

Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.

Snap ring (Reference)

Inside diameter

182.5 mm (7.19 in)

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Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake piston as
shown in the figure.

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Measure the stroke by applying and releasing the
compressed air (390 – 780 kPa, 4 – 8 kg/cm

2

or 57 –

114 psi) as shown in the figure.
Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)
If the values are nonstandard, check for an improper
installation.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-127

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Remove the snap ring.

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Remove two flanges, four plates and four discs.

26. Bearing and race

Coat the bearing and races with petroleum jelly and
install them onto the overdrive support.

Bearing and races diameter (Reference)

Inside

Outside

Bearing

36.5 mm (1.437 in) 48.4 mm (1.906 in)

Race (Front) 37.2 mm (1.465 in) 58.8 mm (2.315 in)

Race (Rear) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

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27. OD planetary ring gear

Install the overdrive planetary ring gear.