Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 667

7A1 – 168 AUTOMATIC TRANSMISSION (4L30-E)

25. Second and Third Clutch Assemblies

1) Carefully align second clutch plates inner tangs.
2) Install thrust washer, tangs pointing downward,

locating tang positioned in slot on second clutch
hub.

NOTE:

Use petroleum jelly to hold thrust washer in place.

3) Install third clutch and intermediate shaft

assembly into the second clutch drum.

4) Install second and third clutch assemblies into the

main case. Twist output shaft and clutch
assemblies to insure proper fit.

5) Install pressure plate with lip side up, tang facing

valve body face.

6) Install reverse clutch plates. Start with a steel

plate and alternate with lined plates.

7) Install waved clutch plate, center tang facing valve

body side.

5-8840-2262-0

Second clutch end play measurement
1) Install the gaging tool on the case flange and

against the intermediate shaft.

2) Position the inner shaft of the gaging tool against

the thrust surface of the second clutch hub.

3) Tighten thumb screw. Remove the tool.
4) Fit the spacer ring on the inner shaft of the tool.
5) Measure gap (“G”). Select appropriate size

washer as the chart specified.

Selective washer gaging tool: 5-8840-2262-0

(J-23085-A)

Selective Thrust Washer

DIM. “G” mm(in)

Color

1.53 - 1.63 (0.060 - 0.064)

YELLOW

1.72 - 1.82 (0.068 - 0.072)

RED

1.91 - 2.01 (0.075 - 0.079)

BLACK

2.10 - 2.20 (0.083 - 0.087)

NATURAL

2.29 - 2.39 (0.090 - 0.094)

GREEN

2.48 - 2.58 (0.098 - 0.102)

BLUE

FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL END-PLAY FROM

0.36mm TO 0.79 mm (.014” TO .031”)

247RW007

AUTOMATIC TRANSMISSION (4L30-E)  7A1 – 169

17. Fourth clutch retainer

18. Fourth clutch plates

18. Turbine shaft and overrun clutch

Turbine shaft

Turbine shaft oil  seal ring

Overrun clutch drum

Overrun clutch piston

2. O-ring

Overrun clutch relase
spring retainer

Roller clutch

Snap ring

Sun gear

Clutch plate

Backing plate

Snap ring

OD 
carrier assembly

20. OD 
    internal gear

21. Thrust
    washer

Diaphragm spring 

Overrun roller clutch cam

24. Fourth clutch piston

23. Snap ring

23. Retainer and spring assembly

Fourth clutch piston

Piston seal

Piston seal

19. Thrust
    bearing

Snap ring

Ratainer and 
ball assembly

7A1 – 170 AUTOMATIC TRANSMISSION (4L30-E)

23. Fourth Clutch Spring Retainer

1) Install retainer and spring assembly.
2) Install snap ring in adapter case.
3) Install compressor.
4) Compress retainer and spring assembly.
5) Seat snap ring in groove.
6) Remove compressor.

Fourth clutch spring compressor: 5-8840-0195-0
(J-23327) and 5-8840-2263-0 (J-23327-90)

22. Adapter Case and Center Support Assembly

1) Install selective washer using petroleum jelly.
2) Install two O-ring seals in main case and adapter

case/main case seal ring.

3) Install guide pins.
4) Install adapter case complete to main case.

Guide pin: 5-8840-2268-0 (J-38588)

24. Fourth Clutch Piston

1) Inspect piston seals and replace if necessary.
2) Lubricate fitter and install on fourth clutch piston.
3) Install fourth clutch piston in adapter case.
4) Remove fitter.

Fourth clutch piston fitter: 5-8840-2267-0 (J-38554)

AUTOMATIC TRANSMISSION (4L30-E)  7A1 – 171

21. Thrust Washer

Install thrust washer into adapter case, with tangs
pointing downwards.

20. Overdrive Internal Gear

19. Thrust Bearing Assembly

18. Turbine Shaft and Fourth Clutch Plates

1) Preassemble overdrive internal gear and thrust

bearing assembly onto the overrun clutch
assembly complete.

NOTE

Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.

2) Complete overdrive carrier and internal gear

assembly into adapter case.

3) Install fourth clutch plates in the following order.

Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.

17. Fourth Clutch Retainer

Install fourth clutch retainer.
Notch facing up and positioned towards valve body
surface.