Isuzu Trooper (1998-2002 year). Service manual - part 735

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–137

REASSEMBLY

248RY00060

Reassembly steps

▲

 1. O-ring

▲

 2. Direct clutch piston

▲

 3. Piston return spring

▲

 4. Snap ring

▲

 5. Disc and plate

▲

 6. Flange

▲

 7. Snap ring.

▲

 8. Clutch drum thrust washer (plastic)

7A–138

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00033

248RY00034

248RY00002

248RY00062

Important operations

1. O-ring

Coat new O-rings with ATF and install them on the direct
clutch piston.

2. Direct clutch piston

Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the direct
clutch piston into the clutch drum, using both hands.

3. Piston return spring

Install piston return spring.

4. Snap ring

Compress piston return spring and install snap ring in
groove.
Place special tool and a suitable ring on the spring retainer,
and compress the return spring.
Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
Spring compressor: 5-8840-0254-0 (J-25048)

5. Disc and plate

Install plates and discs.
Install in order: P– D– P– D– P– D– P– D– P– D
P: Plate, D: Disc

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–139

248RY00035

248RY00036

248RY00029

248RY00061

6. Flange

Install the flange, with the flat side facing downward.

7. Snap ring

Install the snap ring with a screwdriver. Be sure the end
gap of the snap ring is not aligned with the cutout portion of
the direct clutch drum.

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.

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.
There are eight flanges.

mm (in.)

Piston stroke

1.6– 1.9

(0.0630– 0.0748)

mm (in.)

No.

Flange thickness

No.

Flange thickness

33

3.3 (0.130)

37

3.7 (0.146)

34

3.4 (0.134)

38

3.8 (0.150)

35

3.5 (0.138)

39

3.9 (0.154)

36

3.6 (0.142)

40

4.0 (0.158)

7A–140

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00037

248RY00038

8. 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.

Install direct clutch  assembly

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.).