Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1904

7A4-48 UNIT REPAIR (JR405E)

25C&L-SUB27

4. Side plate

Install the side plate.

26C&L-SUB26

5. Snap ring

Install the snap ring to the low clutch drum.

27C&L-SUB58

•

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.

28C&L-SUB32

6. Low clutch piston

•

Install new seal rings to the low clutch piston.

UNIT REPAIR (JR405E) 7A4-49

29C&L-SUB22

•

Install the low clutch piston to the low clutch drum.

30C&L-SUB21

7. Return spring

Install the return spring to the low clutch piston.

31C&L-SUB20

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.

32C&L-SUB18

•

Install the spring compressor to the low clutch.

Spring compressor: 5-8840-2759-0

33C&L-SUB19

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)

34C&L-SUB15

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.

248L300006

11.Snap ring

Install the snap ring to the low clutch drum.

35C&L-SUB38

36CLEAR06

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)

UNIT REPAIR (JR405E) 7A4-51

248L300007

4.2 mm (0.165 in)

4.4 mm (0.173 in)

4.6 mm (0.181 in)

4.8 mm (0.189 in)

37C&L-SUB40

12.Bearing race

13.Rear internal gear

14.Bearing

Install the bearing race and the bearing to the rear internal

gear.

NOTE:
Apply Vaseline to the fitting surfaces of the rear internal
gear to prevent the bearing race and the bearing from
falling during the installation process.

38C&L-SUB43

39C&L-SUB60

•

Install the rear internal gear to the low clutch drum.