Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1795

UNIT REPAIR (JR405E) 7A4-47

Free length – 36.4 mm (1.433 in)

Linear diameter – 1.2 mm (0.047 in)

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Reassembly steps

Coat the parts with ATF before installing them.
1. Bearing

Install the bearing into the low clutch drum.

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2. Snap ring

Install the snap ring to the low clutch drum.

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3. Low one-way clutch

Install the low one-way clutch to the low clutch drum.

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NOTE:
The flanged side of the low one-way clutch must face the
outside.

7A4-48 UNIT REPAIR (JR405E)

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4. Side plate

Install the side plate.

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5. Snap ring

Install the snap ring to the low clutch drum.

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•

Attach the low one-way clutch inner race to the low

clutch drum in the opposite direction of normal position.

•

Rotate the one-way clutch inner race clockwise. It

should turn smoothly with little resistance.

•

Rotate the low one-way clutch inner race

counterclockwise.

It should immediately lock (rotation is impossible).

If it does not, check the low one-way clutch installation

direction.

Inspect and replace the low one-way clutch if required.

•

Remove the low one-way clutch inner race.

•

Reverse the low clutch drum.

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6. Low clutch piston

•

Install new seal rings to the low clutch piston.

UNIT REPAIR (JR405E) 7A4-49

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•

Install the low clutch piston to the low clutch drum.

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7. Return spring

Install the return spring to the low clutch piston.

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8. Cancel cover

•

Carefully center the cancel cover and install it.

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

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•

Install the spring compressor to the low clutch.

Spring compressor: 5-8840-2759-0

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9. Snap ring

•

Use the spring compressor to carefully force the cancel

cover down.

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

•

Install new snap ring to the low clutch drum.

7A4-50 UNIT REPAIR (JR405E)

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10.Dish plate, drive plate, driven plate, and retaining plate

Install the low clutch dish plate (1), the 2 mm thick driven

plate (2), the 7 drive plate (3), the other 6 driven plates (4),

and the retaining plate (5).

NOTE:
Dish plate side with the identification mark must face the
driven plate.

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11.Snap ring

Install the snap ring to the low clutch drum.

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Inspection

•

Insert the low one-way clutch inner race to the low

clutch drum.

•

Force compressed air (392 kPa/4.0 kg/cm

2

) through the

oil passages of the low one-way clutch inner race to

check low clutch operation.

If the low clutch does not operate, the seal rings may be

damaged or the parts may have been installed in the

wrong order.

•

Measure the clearance between the low clutch retaining

plate and the snap ring.

If the clearance is outside the specified range, replace

the existing plate with a new plate of the proper size

(thickness).

Low clutch retaining plate and snap ring clearance:

0.9~1.3 mm (0.035~0.051 in)

Available low clutch retaining plate thicknesses

3.8 mm (0.150 in)

4.0 mm (0.157 in)