wheel torque ISUZU TF SERIES 2004 Owners Manual

7A2-140 DIAGNOSIS (JR405E)
STALL TEST
CAUTION:
Because A/T may break down, do not perform the stall test continuously.

Procedure
1. Chock the four wheels.
2. Warm up the engine.
3. Apply the parking brake.
4. Step on the foot brake fully.
5. Set the select lever to either D, 3, 2, L or R range.
6. Step on the accelerator pedal fully.
7. When the engine speed becomes constant, record tha
t
value quickly.

Stall Speed
Standard: 2600±150 rpm

Evaluation
1. If the stall speed is higher than standard value in all
ranges.

Low line pressure.

Abraded oil pump.

Faulty operation of low clutch.

Adjustment error of or faulty inhibitor switch.


ATF leaking from oil pump, control valve, or
transmission case.

Fixed pressure regulator valve and pilot valve.
2. If the stall speed is higher than standard value in D, 3, 2
and L ranges.

Slip of low clutch.

Slip of low one-way clutch.
3. If the stall speed is higher than standard value in
R
range.

Slip of low & reverse brake.

Slip of reverse clutch.
4. If the stall speed is lower than standard value in all
ranges.

Slip of one-way clutch (in torque converter).

Faulty engine.

DIAGNOSIS (JR405E) 7A2-141
LINE PRESSURE TEST
Procedure
1. Chock the four wheels.
2. Remove the test plug of the transmission case and fit the oil
pressure gauge.
3. Warm up the engine.
4. Apply the parking brake.
5. Step on the foot brake fully.
6.Set the select lever to either D, 3, 2, L or R range.
7. Record the oil pressure at idling.
8. When stepping over the accelerator pedal fully and the
engine speed becomes constant, record the oil pressure
quickly.

Line Pressure
Standard:
Engine Line Pressure (Kpa)
Speed D, 3, 2 or L Range R Range
Idling 350 - 480 450 - 650
Stall 1,050 - 1,250 1.400 - 1,630

Evaluation
1. If the line pressure is lower than standard value at
idling in all ranges.

Abraded oil pump.

Faulty operation of each solenoid.

Sticking of pressure regulator valve or pilot valve.

Fatigued pressure regulator valve or pilot valve spring.


ATF leaking from oil strainer, oil pump, pressure
regulator valve, torque converter relief valve or pressure
relief valve.
2. If the line pressure is lower than standard value at
idling in D, 3, 2 and L ranges.

ATF leaking from low clutch hydraulic circuit.
3. If the line pressure is lower than standard value at
idling in R range.

ATF leaking from reverse hydraulic circuit.

ATF leaking from low and reverse brake hydraulic
circuit.

ON-VEHICLE SERVICE (JR405E) 7A3-3
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20
C (68
F) before the
cold level check is made.
1. Park the vehicle on a level surface.
2. Apply the parking brake firmly.
3. Start the engine and allow it to warm up.
The engine coolant temperature gauge needle
should be midway between the “C” mark and “H”
mark.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each range just long enough for the
transmission to engage.
5. Return the select lever either “P” or “N”.
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.

9. Remove the dipstick.
The ATF level should be inside the “C”range on the
dipstick.
If the ATF level is below the “C” range, ATF must be
added.
242R300002


ATF CHANGE
1. Start the engine and allow it to idle until the ATF
reaches a temperature of 40-50
C
2. Park the vehicle on level ground and block the
wheels.
3. Stop the engine.
4. Raise vehicle and support with suitable safety
stands.
5. Remove the drain plug from the oil pan and drain the
ATF (approximately 6 liters).
6. Remove the oil pan.
7. Inspect the oil pan (details written below).
8. Install the oil pan.
Note:
Use new gasket. Clean the oil pan and magnet.
Oil pan bolt torque : 8 Nm (69 lbin)
9. Replace the gasket and install the drain plug.
Drain plug torque : 35 Nm (26 lbft)
Note:
Do not reuse old washer (gasket).
Clean the drain plug (especially the threaded section).
10. Pour about 5 liters of new ATF. Then, add more ATF
carefully as necessary using the dipstick.
Refer to “ATF LEVEL” previously in this section.
Note:
Keep the engine idle (do not stop it) during the oil level
adjustment.
11. Remove the safety stands and wheel blocks. Inspect
1. Check the drain plug tip for adhesion of foreign
substances.
2. Check the drained ATF for color, smell and inclusion
of foreign substances.
3. Check the oil pan bottom and magnet for adhesion o
f
foreign substances.
If a problem is discovered during those checks, the
Automatic transmission must be overhauled.
Note:
The torque converter and the oil strainer need replaced
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.
In addition, flush the ATF cooler circuit

7A3-6 ON-VEHICLE SERVICE (JR405E)
INHIBITOR SWITCH
The inhibitor switch is attached to the right side of the
transmission.

Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Disconnect the harness connectors.
4. Use a ohmmeter to check the inhibitor switch
continuity between the following terminals as shown
in figure.
5. Place the select lever in the “N” range.
249R300001
6. Move the select lever to either side.
Check the inhibitor switch continuity between the
terminals shown in Step (4).
The continuity readings should remain fairly steady
as the select lever is moved.
If there is no continuity or the continuity is
intermittent, the inhibitor switch must be adjusted.

Adjust
1. Disconnect the shift calbe from the lever.
2. Loosen the inhibitor switch bolts.
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inibitor switch is not correctly adjusted, the
automatic transmission will not function normally.



4. Tighten the 2 inhibitor switch bolts to the specified
touque.
Torque: 5.5 N·m (48 lb·in)
47INH-SW01
5. Connect the shift cable to the lever.
6. Connect the harness connector.

Remove or Disconnect
1. Remove the cable bracket (1) from the transmission.
2. Disconnect the shift cable (2) from the lever (3).
3. Disconnect the harness connectors.
4. Remove the inhibitor switch bolts.
5. Remove the inhibitor switch (4) from the
transmission.

238R300001

ON-VEHICLE SERVICE (JR405E) 7A3-7
Install or Connect
1. Install the inhibitor switch (4) to the transmission.
Temporarily tighten the inhibitor switch bolts.
2. Move the manual shaft select lever to the “N” range.

249R300002
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
4. Tighten the 2 inhibitor switch bolts to the specified
torque.
Torque: 5.5 N·m (48 lb·in)
47INH-SW01
5. Install the cable bracket (1) to the transmission.
6. Connect the shift cable (2) to the lever (3).
7. Connect the harness connector.
8. Connect the negative battery cable.
9. Remove the wheel blocks.

ON-VEHICLE SERVICE (JR405E) 7A3-9
TURBINE SENSOR
The turbine sensor is attached to the right side of the
transmission.

Inspect
1. During the driving at speed of 20km/h (12mph) with
“L” range in low gear, measure the voltage between
the TCM connector terminals (B3) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)
2. If the voltage is out of the standard value, check the
turbine sensor pole piece for presence of foreign
materials and the turbine sensor cable for short o
r
open circuit.
Result of the inspection is normal, replace the
turbine sensor.
Torque: 6 N·m (52 lb·in)



POWER AND 3RD START SWITCH
Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Pry out the switch from the floor console.
4. Disconnect the harness connector.
5. Check continuity between terminal (5) and (6) at third
(3rd) position.
6. Check continuity between terminals (3) and (6) a
t
power (PWR) position.
7. Replace the power and 3rd start switch when the
result of inspection is found abnormal.
8. Connect the harness connector.
9. Connect the negative battery cable.
10. Remove the wheel blocks.
238R300003

ON-VEHICLE SERVICE (JR405E) 7A3-17
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Drain the fluid.
Refer to “ATF CHANGE” in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting
for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign
material, the oil strainer must be replaced.
Further inspection is required to determine the
source of the foreign material.
6. Remove the harness assembly (including oil
temperature sensor).
7. Remove the 11 bolts and the solenoid fixing plate.
8. Remove the 6 solenoids and 3 oil pressure switchs.

Inspect
Oil pressure switch
Apply compressed air (392 kPa/4.0 kg/cm2) to the oil
pressure switch to check the oil pressure switch
continuity between the connector and screw.

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between
harness terminals 7 and 6 (ground).
Oil temperature sensor resistance:
2,400~2,600 ohms (20




C)
244L300011

Solenoid
Measure the resistance of each solenoid.
Resistance:
Brown connector – 3.0~3.4 ohms (20




C)
Gray connector – 12.0~13.2 ohms (20




C)
White connector – 12.2~13.4 ohms (20




C)
Install or connect
1. Install the O-rings to each of the solenoids.
2. Install the 6 solenoids and 3 oil pressure switchs.
Line pressure solenoid bolt torque:
8 N·m (69 lb·in)
Oil pressure switch bolt torque:
4.4 N·m (39 lb·in)
3. Install the solenoid fixing plate together with the
harness brackets.

Number Length (Color)
Solenoid fixing plate bolt
(A)
(B)
4
7
16 mm (0.63 in) (Gold)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (69 lb·in)
4. Install the harness assembly.
5. If removed, install the oil strainer.

Number Length (Color)
Oil strainer bolt
(C)
(D)
9
4
13 mm (0.51 in) (Silver)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (69 lb·in)
6. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
7. Fill the fluid.
Refer to “ATF CHANGE” in this section.
8. Connect the negative battery cable.
9. Remove the wheel blocks.

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.

Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil
Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
6. Fill the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. When the abnormal amount of debris are found.
2. When the abnormal wear or chips on gears and
shafts are found while overhauling.
3. When the abnormal clutch facing wear and oil
contamination are found.

Procedures
1. Block the wheels.
2. Disconnect negative battery cable.
3. Raise vehicle and support with suitable safety
stands.
4. Disconnect fluid cooler lines at transmission case
and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using
solvent and compressed air.
Note:
DO NOT exceed 197 kPa (29 psi) air pressure or
damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic
Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (33 lb·ft)
8. Replenish ATF
9. Start engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all
debris from the fluid cooler circuit.
Move the select lever through the various ranges and
return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF
must be added.
10. Connect negative battery cable.
11. Remove safety stands.
12. Remove wheel blocks.

7A3-22 ON-VEHICLE SERVICE (JR405E)

4. Install the 3rd crossmember.
Bolt and Nut torque : 67 N·m (49 lb·ft)
Bolt torque : 50 N·m (37 lb·ft)
5. Install the automatic transmission fluid cooling pipe.
6. Install the torque converter bolts.
Bolt torque : 29 N·m (22 lb·ft)
7. Install the undercover.
Bolt torque : 9 N·m (78 lb·in)
8. Install the ATF level dipstick and tube.
9. Install the fuel hose bracket.
Bolt torque : 6 N·m (52 lb·in)

10. Tighten the nuts securing the exhaust manifold and
the exhaust pipe.
Bolt torque : 43 N·m (32 lb·ft)
11. Install the rear propeller shaft assembly.
Flange bolt torque : 63 N·m (46 lb·ft)
Center bearing bracket bolt torque :
69 N·m (51 lb·ft)
12. Install the shift cable.
13. Connect the negative battery cable.
14. Remove the safety stands.
15. Remove the wheels blocks.


Torque Specifications
RTW37ALF001501