Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1803

UNIT REPAIR (JR405E) 7A4-79

38OUTPUT25

29ASSY089

18.Output shaft

•

Install a new seal ring to the output shaft assembly.

•

Measure the gap between the seal ring and the ring

groove.

If the gap is outside the specified range, the output shaft

must be replaced.

Seal ring and ring groove gap:

0.10~0.25 mm (0.0039~0.0098 in)

•

Install the bearing to the case.

NOTE:

••••

Apply Vaseline to the bearing (with bearing race).

••••

The black side (bearing race) of the bearing must be

visible.

40ASSY091

•

Push the output shaft into place.

19.Rear extension (2WD) or adapter case (4WD)

•

Use the oil seal installer to install the oil seal to the rear

extension (2WD) or adapter case (4WD).

Oil seal installer:

5-8840-2769-0 (2WD)

5-8840-2770-0 (4WD)

41ASSY096

•

Install the bearing (with bearing race) to the rear

extension (2WD) or adapter case (4WD).

NOTE:

••••

The black side (bearing race) of the bearing must be

visible.

••••

Apply Vaseline to the bearing.

7A4-80 UNIT REPAIR (JR405E)

249L300005

•

Apply sealing agent (TB1216B) to the rear extension

(2WD) or adapter case (4WD) contact surfaces.

249L300006

•

Install the rear extension (2WD) or adapter case (4WD)

to the transmission case and tighten the 10 bolts to the

specified torque.

Torque: 53 N

⋅⋅⋅⋅

m (39 Ib

⋅⋅⋅⋅

ft)

43ASSY119

20.Control valve assembly

•

Align the manual valve and the manual plate of the

transmission case.

•

Install the control valve assembly and tighten the 12

fixing bolts to the specified torque.

Number of bolts

Length

Color

10 (A)

40 mm (1.57 in)

Gold

2 (B)

30 mm (1.18 in)

Gold

44ASSY121

Torque: 8 N

⋅⋅⋅⋅

m (69 Ib

⋅⋅⋅⋅

in)

UNIT REPAIR (JR405E) 7A4-81

45CV29

•

Connect the harness assembly and control valve

assembly connectors.

244L300001

21.Oil pan

•

Install a new gasket and the oil pan.

•

Tighten the bolts to the specified torque.

Torque: 8 N

⋅⋅⋅⋅

m (69 Ib

⋅⋅⋅⋅

in)

7A4-82 UNIT REPAIR (JR405E)

47INH-SW01

22.Inhibitor switch

•

Secure the inhibitor switch (1) by hand-tightening the 2

bolts.

•

Use the inhibitor switch set plate to align the neutral

holes (manual shaft and inhibitor switch).

Turn the inhibitor switch to adjust it.

Inhibitor switch set plate: 5-8840-2763-0

NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.

•

Tighten the 2 inhibitor switch bolts to the specified

torque.

Torque: 5.5 N

⋅⋅⋅⋅

m (48 Ib

⋅⋅⋅⋅

in)

•

Remove the holding fixture from the transmission case.

240L300001

23.Speed sensor and turbine sensor

•

Apply ATF to the new O-rings and install them the

speed sensor (2) and the turbine sensor (3).

•

Install the speed sensor and the turbine sensor. Tighten

the bolt to the specified torque.

Torque: 6 N

⋅⋅⋅⋅

m (52 Ib

⋅⋅⋅⋅

in)

24.Torque converter

•

Pour the new ATF into the torque converter.

•

Shake the torque converter to thoroughly clean the

inside.

•

Drain the ATF from the torque converter.

•

Pour the new ATF into the torque converter.

NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.

A07L300003

•

Install the torque converter.

•

Measure the torque converter end play (A).

If the measured value is greater than the specified

minimum, the torque converter is correctly installed.

Torque converter end pay (Minimum): 67 mm (2.64

in)