Isuzu Trooper (1998-2002 year). Manual - part 734

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–133

DIRECT CLUTCH ASSEMBLY (C-2)

DISASSEMBLY

248RY00059

Disassembly steps

1. Clutch drum thrust washer

2. Snap ring

3. Flange

4. Plate and disc

▲

 5. Snap ring

6. Piston return spring

▲

 7. Direct clutch piston

8. O-ring

7A–134

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00028

248RY00029

248RY00061

248RY00002

Important operations

Remove direct clutch drum assembly from forward clutch
assembly.

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 (4– 8 kg/
cm

2

, 57– 114 psi or 392– 785 kPa) as shown.

5. Snap ring

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

mm (in.)

Piston stroke

1.6– 1.9

(0.0630– 0.0748)

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–135

248RY00030

247RY00034

252RY00027

248RY00031

7. Direct clutch piston

Place the direct clutch drum onto the OD support. 
Holding the direct clutch piston by hand, apply compressed
air to the OD support to remove the direct clutch piston.
Remove the direct clutch piston.
Remove two O-ring from piston.

INSPECTION AND REPAIR

Check piston return spring

Using calipers, measure the free length of the return spring.

Check discs

Using a micrometer, measure the thickness of the discs.

If the thickness is less than the minimum, replace the disc.

Check direct clutch piston

Check that check ball is free by shaking the piston. 
Check that the valve does not leak by applying low-pressure
compressed air.

mm (in.)

Standard

21.3 (0.839)

mm (in.)

Minimum thickness

1.84 (0.0724)

7A–136

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00032

Check direct clutch drum bushing

Using a dial indicator, measure the inside diameter of the
clutch drum bushing.

If the inside diameter is grater than maximum, replace the
clutch drum.

mm (in.)

Maximum inside diameter

53.99 (2.1256)