Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 399

7A-144 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00001

14. Snap ring

Place special tool on the spring retainer, and compress
the return spring.
Spring compressor : 5-8840-0195-0 (J-23327-1)
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.

252RY00038

15. Flange, disc and plate

Install two plates and tow discs then install the flange,
with the flat side facing downward.

252RY00039

16. Snap ring

Install snap ring.

252RY00017

Check piston stroke of OD direct clutch (C-0)

Place the oil pump onto the torque converter, and then
place the OD direct clutch assembly onto the oil pump.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-145

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

2

or 57 – 114 psi) as

shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification, replace
the disc and recheck the piston stroke.
If the piston stroke is non standard, select another
flange.

Flange sizes

Flange

thickness Flange

thickness

3.8 mm (0.150 in)

3.4 mm (0.134 in)

3.7 mm (0.146 in)

3.3 mm (0.130 in)

3.6 mm (0.142 in)

3.2 mm (0.126 in)

3.5 mm (0.138 in)

3.1 mm (0.122 in)

252RY00018

17. Thrust bearing

Coat the assembled bearing and race with petroleum
jelly and install it with the race side facing downward.

Bearing and race (Reference)

Inside diameter

28.9 mm (1.138 in)

Outside diameter

50.2 mm (1.976 in)

252RY00040

252RY00016

18. OD direct clutch assembly

Align the flukes of discs in the direct clutch.
Install the OD direct clutch assembly onto the OD
planetary gear.

252RY00015

Check operation of one-way clutch

Hold the OD direct clutch drum and turn the input shaft.
The input shaft should turn freely clockwise and should
lock counterclockwise.

○

1

: Free

○

2

: Lock

7A-146 AUTOMATIC TRANSMISSION (AW30-40LE)

OD SUPPORT ASSEMBLY

DISASSEMBLY

252R200003

Disassembly steps

1. Thrust

bearing

2. Race
3. Thrust washer (plastic)
4. Snap

ring

5. Piston

return

spring

6. OD brake piston
7. O-ring
8. Oil seal ring
9. OD

support

252RY00042

Disassembly steps

Check OD brake piston movement

Place the OD support assembly onto the direct clutch
assembly.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-147

252RY00043

Apply compressed air into the oil passage as shown,
and be sure that the OD brake piston moves smoothly.

1. Thrust bearing
2. Race
3. Thrust washer (plastic)

252RY00044

4. Snap ring

Place special tool on the spring retainer, and compress
the return spring with a shop press.
Spring compressor : 5-8840-2170-0 (J-37233)
Remove the snap ring with a screwdriver.

5. Piston return spring

252RY00045

6. OD brake piston

Place the OD support onto the direct clutch assembly.
Hold the OD brake piston so it is not slanted and apply
compressed air into the passage to remove the OD
brake piston.
Remove the OD brake piston.

7. O-ring
8. OD seal ring
9. OD support

INSPECTION AND REPAIR

Make necessary correction or parts replacement if
wear, damage or any abnormal conditions are found
through inspection.

252RY00046

Check piston return spring

Using calipers, measure the free length of the return
spring.
Standard length: 17.03 mm (0.6705 in)