Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1906

7A4-56 UNIT REPAIR (JR405E)

05CASE-AY30

2. Parking rod

•

Use a pin punch to force out the parking rod spring pin.

06CASE-AY37

•

Rotate the manual plate as you pull the parking rod free.

08CASE-AY45

3. Detent spring

Remove the fixing bolt and the detent spring.

09CASE-AY28

4. Manual shaft and manual plate

•

Remove the manual shaft spring pin.

10CASE-AY21

•

Remove the manual shaft together with the manual

plate.

UNIT REPAIR (JR405E) 7A4-57

11CASE-AY01

5. Oil seal

Using a screwdriver, remove the oil seal from the

transmission case.

Inspection

2 – 4 brake drive plate

Measure the 2-4 brake drive plate facing thickness at 3

points and calculate the average value.

If the average value is less than the specified limit, the 2-4

brake drive plate must be replaced.
2 – 4 brake drive plate facing thickness:

Standard = 2.0 mm (0.079 in)

Limit = 1.8 mm (0.071 in)

Low and reverse brake drive plate

Measure the low and reverse brake drive plate facing

thickness at 3 points and calculate the average value.

If the average value is less than the specified limit, the low

and reverse drive plate must be replaced.

Low and reverse brake drive plate facing thickness:

Standard = 2.0 mm (0.079 in)

Limit = 1.8 mm (0.071 in)

2 – 4 brake return spring

•

Check the number of effective 2-4 brake return spring

coils.

Effective return spring coils (Standard): 10.2

•

Measure the 2-4 brake return spring outside diameter,

free length, and linear diameter.

If any of the measured values exceed the specified limit,

the 2-4 brake return spring must be replaced.

2 – 4 brake return spring measurements (Standard):

Outside diameter = 6.9 mm (0.272 in)

Free length = 22.5 mm (0.886 in)

Linear diameter = 1.1 mm (0.043 in)

Low and reverse brake return spring

•

Check the number of effective low and reverse brake

return spring coils.

Effective return spring coils (standard): 4.8

•

Measure the low and reverse brake return spring

outside diameter, free length, and linear diameter.

If any of the measured values exceed the specified limit,

the low and reverse return spring must be replaced.

Low and reverse brake return spring measurements

(Standard):

Outside diameter = 11.2 mm (0.441 in)

7A4-58 UNIT REPAIR (JR405E)

Free length = 22.3 mm (0.878 in)

Linear diameter = 1.1 mm (0.043 in)

12CASE-AY06

Reassembly steps

1. Oil seal, manual shaft, and manual plate

•

Use the oil seal installer to force the manual plate oil

seal into place.

Oil seal installer: 5-8840-2758-0

14CASE-AY21

•

Install the manual shaft together with the manual plate.

15CASE-AY26

•

Drive the spring pin into the transmission case.

16CASE-AY37

2. Parking rod

•

Rotate the manual plate while installing the parking rod.

UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43

•

Use a pin punch to drive the manual plate spring pin into

place.

21CASE-AY48

3. Detent spring

•

Install the detent spring and tighten the fixing bolt to the

specified torque.

Torque: 7 N

⋅⋅⋅⋅

m (61 Ib

⋅⋅⋅⋅

in)

23CASE-AY53

4. Harness assembly

•

Apply automatic transmission fluid to the new O-ring and

install them to the harness assembly.

•

Install the harness assembly to the transmission case.

Tighten the fixing bolt to the specified torque.

Torque: 6 N

⋅⋅⋅⋅

m (52 Ib

⋅⋅⋅⋅

in)

24ASSY003

5. Low one-way clutch inner race

•

Install new seal rings to the low one-way clutch inner

race.

25ASSY126

•

Measure the gap between the seal ring and the ring

groove.

If the measured valve is outside the specified range the

low one-way clutch inner race must be replaced.

Sealing ring and ring groove gap:

0.10~0.25 mm (0.0004~0.001 in)