Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1900

7A4-32 UNIT REPAIR (JR405E)

18PUMP07

5. Oil pump cover

6. Oil pump housing

Install the oil pump cover to the oil pump housing.

Tighten the 8 bolts to the specified torque.

Torque: 9 N

⋅⋅⋅⋅

m (78 Ib

⋅⋅⋅⋅

in)

7. O-ring (large)

Install the O-ring (large) to the oil pump cover.

8. Seal ring

Install the 4 seal rings to the oil pump cover.

UNIT REPAIR (JR405E) 7A4-33

CLUTCH PACK (REVERSE AND

HIGH CLUTCH ASSEMBLY)

01R&H17

Legend

1. Reverse and high clutch drum

2. Seal ring (reverse clutch)

3. Lip seal (reverse clutch)

4. Reverse clutch piston

5. Seal ring (small, high clutch)

6. Seal ring (large, high clutch)

7. High clutch piston

8. Return spring

9. High clutch cover

10. Snap ring

11. Dish plate (high clutch)
12. Driven plates (5, high clutch)
13. Drive plates (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plates (2, reverse clutch)
18. Drive plates (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)

02R&H18

Disassembly steps

1. Snap ring

Remove the reverse clutch snap ring.

7A4-34 UNIT REPAIR (JR405E)

03R&H21

2. Retaining plate, drive plate, driven plate and dish plate

Remove the reverse clutch retaining plate, the 2 drive

plates, the 2 driven plates, and the dish plate.

04R&H22

3. Snap ring

Remove the high clutch snap ring.

05R&H25

4. Retaining plate, drive plate, driven plate and dish plate

Remove the high clutch retaining plate, the 5 drive plates,

the 5 driven plates, and the dish plate.

07R&H28

5. Snap ring

6. High clutch cover

7. Return spring

•

Install the spring compressor to the reverse and high

clutch drum.

Spring compressor: 5-8840-2767-0

•

Carefully press the high clutch cover down .

Take care not to damage the return spring.

•

Remove the snap ring.

•

Remove the high clutch cover and the return spring.

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.

09R&H37

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)