Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 402

7A-156 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00029

Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support
assembly.

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)
If the piston stroke is not within specification, replace
the discs and recheck the piston stroke.
If the piston stroke is non standard, select another
flange.

Flange sizes

Flange thickness

Flange thickness

3.3 mm (0.130 in)

3.8 mm (0.150 in)

3.4 mm (0.134 in)

3.9 mm (0.154 in)

3.5 mm (0.138 in)

4.0 mm (0.157 in)

3.6 mm (0.142 in)

4.1 mm (0.161 in)

3.7 mm (0.146 in)

4.2 mm (0.165 in)

248RY00061

248RY00037

9. Clutch drum thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it
onto the direct clutch.
NOTE :
Make sure that the lugs fit into the cutout portions
on the direct clutch.

248RY00038

Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that the distance from the direct clutch end to the
forward clutch end is 71.2 mm (2.803 in).

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-157

FORWARD CLUTCH ASSEMBLY

(C-1)

DISASSEMBLY

248R200003

Disassembly steps

1. Thrust

bearing

2. Race
3. Snap

ring

4. Flange
5. Disc

and

plate

6. Cushion

plate

7. Snap

ring

8. Piston return spring
9. Piston
10. O-ring
11. O-ring
12. Oil seal ring
13. Thrust bearing
14. Forward clutch drum

7A-158 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00039

Disassembly steps

Remove forward clutch assembly from direct clutch
assembly.

248RY00048

1. Thrust bearing
2. Race

Place wooden blocks, etc. to prevent forward clutch
shaft from touching the work stand, and place the OD
support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.

248R200008

Check piston stroke of forward clutch (C-1)

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

2

or 57 – 114 psi) as

shown.
Pack clearance: 0.5 – 0.9 mm (0.020 – 0.035 in)

248RY00041

3. Snap ring

Remove snap ring from clutch drum.

4. Flange
5. Disc and plate
6. Cushion plate

248RY00003

7. Snap ring

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

8. Piston return spring

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-159

248RY00042

9. Piston

Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.

10. O-ring
11. O-ring
12. Oil seal ring
13. Thrust bearing
14. Forward clutch drum

248RY00031

INSPECTION AND REPAIR

Check forward 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.

248RY00043

Check forward clutch drum bushing

Using a dial indicator, measure the inside diameter of
the forward clutch drum bushing.
Maximum inside diameter: 24.01 mm (0.9453 in)
If the inside diameter is greater then the maximum,
replace the forward clutch drum.

248RY00045

Check disc, plate and flange

Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.

・ If the lining of the disc is peeling off or discolored, or

even if parts of the printed numbers are defaced,
replace all discs.

・ Before assembling new discs, soak them in ATF for

at least fifteen minutes.