Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 340

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-209

248RY00029

Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support
assembly.

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

2

or 57 – 114 psi) as shown.

Piston stroke: 1.6 – 1.9 mm (0.0630 – 0.0748 in)

(UBS)

Pack clearance: 0.4 – 0.7 mm (0.0157 – 0.0276 in)

(TFR/S)

If the piston stroke is not within specification, replace
the discs and recheck the piston stroke.
If the piston stroke is non standard, select another
flange.

Flange sizes

Flange thickness

Flange thickness

3.3 mm (0.130 in)

3.8 mm (0.150 in)

3.4 mm (0.134 in)

3.9 mm (0.154 in)

3.5 mm (0.138 in)

4.0 mm (0.157 in)

3.6 mm (0.142 in)

4.1 mm (0.161 in)

3.7 mm (0.146 in)

4.2 mm (0.165 in)

248RY00061

248RY00037

9. Clutch drum thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it
onto the direct clutch.
NOTE :
Make sure that the lugs fit into the cutout portions
on the direct clutch.

7A-210 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00038

Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward
clutch assembly.
Check that the distance from the direct clutch end to
the forward clutch end is 71.2 mm (2.803 in).

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-211

FORWARD CLUTCH ASSEMBLY

(C-1)

DISASSEMBLY

248R200003

Disassembly steps

1. Thrust

bearing

2. Race
3. Snap

ring

4. Flange
5. Disc

and

plate

Six discs and six plates (UBS)
Five discs and five plates (TFR/S)

6. Cushion

plate

7. Snap

ring

8. Piston return spring
9. Piston
10. O-ring
11. O-ring
12. Oil seal ring
13. Thrust bearing
14. Forward clutch drum

7A-212 AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00039

Disassembly steps

Remove forward clutch assembly from direct clutch
assembly.

248RY00048

1. Thrust bearing
2. Race

Place wooden blocks, etc. to prevent forward clutch
shaft from touching the work stand, and place the OD
support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.

248R200008

Check piston stroke of forward clutch (C-1)

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

2

or 57 – 114 psi) as

shown.
Pack clearance: 0.6 – 1.0 mm (0.0236 – 0.0394 in)

(UBS)

: 0.5 – 0.9 mm (0.0197 – 0.0354 in)

(TFR/S)

248RY00041

3. Snap ring

Remove snap ring from clutch drum.

4. Flange
5. Disc and plate
6. Cushion plate

248RY00003

7. Snap ring

Place special tool on the sparing retainer and compress
the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : 5-8840-0254-0 (J-25048)

8. Piston return spring