Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 324

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

DISASSEMBLY OF MAJOR

COMPONENTS (1)

240R200036

Disassembly steps

1. Torque converter
2. Transmission control rod and select

lever (UBS and TFR/S)

3. Transmission control rod and select

lever (’01 TFR)

4. Neutral start switch
5. Elbow
6. Oil temperature sensor
7. Breather hose

8. Input revolution sensor
9. Output revolution sensor (4×4)

10. Output revolution sensor (4×2)
11. Speedometer sensor, speedometer

driven gear and plate (4

× 2)

12. Extension housing (4

× 2)

13. Adapter housing (4

× 4)

14. Transmission assembly

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

Disassembly steps

1. Torque

converter

2. Transmission control rod and select lever (UBS and

TFR/S)

3. Transmission control rod and select lever (’01 TFR)

249RW003

4. Neutral start switch

Unstake the lock washer.

Remove the nut and bolts, and then remove the neutral

start switch.

Remove the lock washer and grommet.

240RY00001

5. Elbow

Remove two elbows from transmission case.

6. Oil temperature sensor
7. Breather hose
8. Input revolution sensor
9. Output revolution sensor (4×

×

×

×4)

10. Output revolution sensor (4×

×

×

×2)

11. Speedometer sensor, speedometer driven gear and

plate (4

×××× 2)

12. Extension housing (4

×××× 2)

13. Adapter housing (4

×××× 4)

240R200021

14. Transmission assembly

Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (J-37227)
Holding fixture base: 5-8840-0003-0 (J-3289-20)

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

REASSEMBLY OF MAJOR

COMPONENTS (1)

240R200035

Reassembly steps

1. Transmission

assembly

2. Extension housing (4×2)
3. Speedometer driven gear, plate, and

speedometer sensor (4×2)

4. Adapter housing (4×4)
5. Neutral start switch
6. Oil

temperature

sensor

7. Elbow

8. Transmission control rod and select

lever (UBS and TFR/S)

9. Transmission control rod and select

lever (’01 TFR)

10. Output revolution sensor (4×2)
11. Output revolution sensor (4×4)
12. Input revolution sensor
13. Breather hose
14. Torque converter

Reassembly steps

1. Transmission assembly
2. Extension housing (4×

×

×

×2)

Install a new gasket and the extension housing to the

transmission case.

Torque: 36 N････m (3.7 kg････m/27 Ib････ft)

7A-148 AUTOMATIC TRANSMISSION (AW30-40LE)

3. Speedometer driven gear, plate, and speedometer

sensor (4×

×

×

×2)

Torque:
Plate bolt – 15 N････m (1.5 kg････m/11 Ib････ft)
Speedometer sensor – 25 N････m (2.5 kg････m/18 Ib････ft)

241RY00020

4. Adapter housing (4×

×

×

×4)

Remove any gasket material on the contacting surfaces

of the adapter housing and transmission case.

Apply liquid gasket (TB1281-B or its equivalent) (1) and

install the apply gaskets (2) to the adapter housing as
shown in the figure.

Install the adapter housing to the transmission case.
Torque: 34 N････m (3.5 kg････m/25 Ib････ft)

249L100003

5. Neutral start switch

Using the transmission select lever, fully turn the
manual valve lever shaft back and return two notches.
It is now in neutral.
Insert the neutral start switch onto the manual valve
lever shaft and temporarily tighten the adjusting bolt.
Install the lock washer and nut.
Torque: 7 N････m (0.7 kg････m/61 Ib････in)
Align the neutral standard line and the switch groove
and tighten the adjusting bolt.
Torque: 13 N････m (1.3 kg････m/113 Ib････in)
Bend the tabs of the lock washer.
NOTE:
Bend at least two of the lock washer tabs.

249L100001

6. Oil temperature sensor

Install the oil temperature sensor to the transmission
case.
Torque: 15 N････m (1.5 kg････m/11 Ib････ft)