transmission oil ISUZU TF SERIES 2004 Workshop Manual

7A2-4 DIAGNOSIS (JR405E)
PAGE
NO. D3: GEAR SHIFT POINT IS LOW OR HIGH AT ALL POINT................................. 7A2-120
NO. D4: GEAR SHIFT POINT IS LOW OR HIGH AT LIMITED POINT ......................... 7A2-120
NO. D5: NO KICK-DOWN .............................................................................................. 7A2-120
NO. E1: NO GEAR SHIFT .............................................................................................. 7A2-121
NO. E2: ONLY 4TH GEAR (O/D) IS NOT SELECTABLE ............................................. 7A2-124
NO. E3: GEAR IS SHIFTED 2ND TO 3RD IN 2 RANGE ............................................... 7A2-126
NO. E4: GEAR IS SHIFTED 1ST TO 2ND IN L RANGE................................................ 7A2-126
NO. E5: GEAR IS SHIFTED 3RD TO 4TH IN 3 RANGE................................................ 7A2-126
NO. F1: LOW MAXIMUM SPEED OR POOR ACCELERATION ................................... 7A2-127
NO. F2: ENGINE RACES UP DURING ACCELERATION (SLIP) ................................. 7A2-130
NO. F3: NOISE OR VIBRATION DURING THE RUNNING IN R, D, 3, 2 OR L
RANGE .......................................................................................................................... 7A2-130
NO. F4: ENGINE BRAKE DOES NOT APPLY IN L RANGE......................................... 7A2-130
NO. F5: ENGINE STALLS BEFORE VEHICLE STOPS FROM RUNNING ................... 7A2-131
NO. G1: VEHICLE MOVES IN P RANGE OR PARKING GEAR IS NOT
DISENGAGED OTHER THAN P RANGE ..................................................................... 7A2-131
NO. G2: CREEP FORCE IS LARGE.............................................................................. 7A2-131
NO. G3: CREEP FORCE IS SMALL .............................................................................. 7A2-132
NO. G4: LARGE NOISE DURING IDLING WITH THE VEHICLE IN STOP STATE ...... 7A2-133
NO. H1: JUDDER OCCURS AT THE LOCK-UP ........................................................... 7A2-133
NO. H2: LARGE LOCK-UP SHOCK .............................................................................. 7A2-133
NO. H3: LOCK-UP POINT IS HIGH OR LOW ............................................................... 7A2-133
NO. I1: NO LOCK-UP .................................................................................................... 7A2-134
NO. J1: OIL LEAKS FROM BREATHER ....................................................................... 7A2-136
NO. J2: OIL LEAKS BETWEEN ENGINE AND CONVERTER HOUSING .................... 7A2-136
NO. J3: OIL LEAKS BETWEEN MAIN CASE AND CONVERTER HOUSING.............. 7A2-136
NO. J4: OIL LEAKS BETWEEN MAIN CASE AND REAR HOUSING .......................... 7A2-136
NO. J5: OIL LEAKS FROM OIL PAN ............................................................................ 7A2-136
NO. J6: OIL LEAKS FROM MANUAL SHAFT OIL SEAL ............................................. 7A2-136
NO. J7: OIL LEAKS FROM OIL COOLER PIPE JOINT................................................ 7A2-136
NO. Z1: TRANSMISSION OVERHEAT .......................................................................... 7A2-136
NO. Z2: MODE LAMP (POWER DRIVE OR 3RD START) DOES NOT LIGHT UP
WHEN THE POWER MODE OR 3RD START MODE IS TURNED ON........................ 7A2-137

7A2-12 DIAGNOSIS (JR405E)
F0: Diagnostic Trouble Code
F0: Read DTC Infor As Stored By ECU
F1: Clear DTC Information
F1: Data Display
F2: Snapshot
F3: Miscellaneous Test
F0: Lamp
F0: Power Lamp Test
F1: 3rd Start Lamp Test
F2: AT Oil Temperature Lamp Test
F3: Transmission Check Light Test
F1: Solenoids
F0: Low & Reverse Brake Solenoid
F1: 2-4 Brake Solenoid
F2: High Clutch Solenoid
F3: Low Clutch Solenoid
F4: Line Pressure Solenoid
F5: Lock Up Duty Solenoid
F4: Programming
F0: Program VIN
F1: Lock ECU

F0: Diagnostic Trouble Code
The purpose of the "Diagnostic Trouble Codes" mode is to
display stored trouble code in the TCM.
When "Clear DTC Information" is selected, a "Clear DTC
Information", warning screen appears. This screen informs you
that by cleaning DTC's "all stored DTC information in the TCM
will be erased".
After clearing codes, confirm system operation by test driving
the vehicle.

F1: Data Display
The purpose of the "Data Display" mode is to continuously
monitor data parameters.
The current actual values of all important sensors and signals
in the system are display through F1mode.
See the "Typical Scan Data" section.

F2: Snapshot
"Snapshot" allows you to focus on making the condition occur,
rather than trying to view all of the data in anticipation of the
fault. The snapshot will collect parameter information around a
trigger point that you select.

F3: Miscellaneous Test:
The purpose of "Miscellaneous Test" mode is to check for
correct operation of electronic system actuators.

F4: Programming (Factory Use Only):
The purpose of "Programming" is to program VIN in the ECM
and lock the programmed data.

7A2-14 DIAGNOSIS (JR405E)
MISCELLANEOUS TEST
The state of each circuit can be tested by using miscellaneous test menus. Especially when DTC cannot be
detected, a faulty circuit can be diagnosed by testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using these menus could help discriminate between a mechanical
trouble and an electrical trouble.

Connect Tech 2 and select "Powertrain", "JR 405E" & "Miscellaneous Test".
F0: Lamps
The circuit is normal if the warning light in the meter panel comes on and goes out in accordance with Tech 2
instruction.

Lamps

F0: Power Lamp Test
F1: 3rd Start Lamp Test
F2: AT Oil Tempeature Lamp Test
F3: Transmission Check Light Test


F0: Power Lamp Test


Power Lamp Test

Power Lamp Off



 Press "Active" key.
Then, "POWER DRIVE" indicator lamp is turned on in the meter panel.
 Press "Inactive" key.
Then, "POWER DRIVE" indicator lamp is turned off in the
meter panel.
 Press "Quit" Key to cancel the test.
F1: 3rd Start Lamp Test
F2: AT Oil Temperature Lamp Test
F3: Transmisstion Check Light Test
Test procedure is same as "F0: Power Lamp Test".
The circuit is normal if the warning light in the meter panel
comes on and goes out in accordance with Tech 2 instruction.

F1: Solenoids
The circuit is normal if clicking sound is generated in accordance with Tech 2 instruction.

Solenoids
F0: Low & Reverse Brake Solenoid
F1: 2-4 Brake Solenoid
F2: High Clutch Solenoid
F3: Low Clutch Solenoid
F4: Line Pressure Solenoid
F5: Lock Up Duty Solenoid

DIAGNOSIS (JR405E) 7A2-77
Step Action Yes No
6 Is the quantity of ATF correct?
Go to Step 7
Correct the quantity of
ATF.
Go to Step 9
7 Connect the Tech 2 and test the solenoids of respective
solenoids for low & reverse brake, 2-4 brake, high clutch and
low clutch. Is operation sound heard from each solenoid?
Go to Step 8
Replace the solenoid
that does not generate
the operation sound.
Go to Step 9
8 Check the line pressure during the idling and at the engine stall
speed. Is the line pressure correct?
Go to Step 10
Either control valve, oil
pump or power train
parts (clutch, brake)
will be faulty. Replace
or overhaul the
transmission unit.
Go to step 10
9 Run the vehicle, and is the gear shifted from 1st to 4th
correctly?
Go to Step 10
Either control valve, oil
pump or power train
parts (clutch, brake)
will be faulty. Replace
or overhaul the
transmission unit.
Go to step 10
10 Clear the DTC from the memory and perform the work after
repair. Is the same DTC code outputted again in the
subsequent DTC check?
Replace the TCM Go to Step 11
11 Are the other DTCs outputted?
Go to Other DTC
Section Action is completed

DIAGNOSIS (JR405E) 7A2-91
SYMPTOM DIAGNOSIS

Symptom Condition Description
Oil Leak Breather Oil leaks from breather. J1
Between engine and converter housing Oil leaks between engine and converter
housing. J2
Between converter housing and main caseOil leaks between converter housing and
main case. J3
Between main case and rear housing Oil leaks between main case and rear
housing. J4
Oil pan Oil leaks from oil pan. J5
Manual shaft oil seal Oil leaks from manual shaft oil seal. J6
Oil cooler pipe Oil leaks from oil cooler pipe joint. J7
Other Transmission overheat You smell the transmission burning. Z1

The transmission smokes.
Mode lamp does not light up when the
power mode or 3rd start mode is turned on
The mode lamp on the instrument panel
does not light up though the power mode or
3rd start mode is turned on with the ignition
switch in ON position.
Z2
Mode lamp lights up when the power mode
or 3rd start mode is turned off
The mode lamp on the instrument panel
lights up though the power mode or 3rd start
mode is turned off with the ignition switch in
ON position.
Z3
Oil temperature warning lamp lights up Sometimes, the oil temperature warning
lamp lights up. Z4
Select lever feeling is faulty Select lever feeling is faulty. Z5
Poor fuel consumption Poor fuel consumption. Z6
Pattern select switch is faulty Shift pattern does not change though the
pattern select switch is turned on. Z7
Oil is splashed during the running Oil is splashed during the running. Z8
Abnormal smell Abnormal smell. Z9
Oil quantity is low or high Oil quantity is low or high. Z10
Abnormal oil pressure Oil pressure is low or high. Z11
Reverse buzzer does not ring Reverse buzzer does not ring in R range. Z12

DIAGNOSIS (JR405E) 7A2-133
No. G4: Large Noise During Idling with the Vehicle in Stop State

Description:

The transmission is noisy during the idling speed in all ranges.

Diagnosis Hints:

Causes such as solenoid operating sound or faulty oil pump are considered.

Distinguishing to some extent is possible by stopping the solenoid operation temporarily, checking the correlation
for the former case and, changing the line pressure and confirming the correlation with noise.

As a matter of course, noise may be generated around the engine, for instance, other than the AT and should be
checked carefully.
Note:
When the noise is generated only at the time of gear shift, it may be the sound of flowing ATF or gear
noise. If the sound varies depending on the gear speed to be shifted, it may be the gear noise generated
from the planetary gear and its related components. If the sound varies depending on the vehicle
speed, it may be the gear noise of the output system, and if varying depending on the engine speed, it
may be the gear noise of the input system or faulty torque converter.
In either case, sound may be "noise" depending on the origin and resonance object. When the object
generating the sound (resonance object) and the sound source (vibration source) are different,
investigation of the cause may be difficult.





No. H1: Judder Occurs at the Lock-up

Diagnosis Hints:

The vehicle body judders at lock-up.

Diagnosis Hints:

Slip due to burning of the lockup piston or insufficient fastening due to dropped working pressure are considered.
Trouble diagnosis flow is basically the same as "No. I1: No lock-up".
Note:
When the lock-up piston has burnt, foreign material mixed in the oil cooler is considered. In such a
case, inspect the oil cooler circuit for clogging of the oil cooler.





No. H2: Large Lock-up Shock
No. H3: Lock-up Point is High or Low

Description:

Large shock is felt at lock-up.

Lock-up point is excessive high or low.

Diagnosis Hints:

Out of properties of input sensor or faulty lock-up piston pressure system are considered.

Trouble diagnosis flow is basically the same as "No. I1: No lock-up".

7A2-136 DIAGNOSIS (JR405E)
No. J1: Oil Leaks from Breather

Description:

Oil leaks from breather.

Possible Cause:

ATF quantity is excessively.




No. J2: Oil Leaks Between Engine and Converter Housing
No. J3: Oil Leaks Between Main Case and Converter Housing
No. J4: Oil Leaks Between Main Case and Rear Housing
No. J5: Oil Leaks from Oil Pan
No. J6: Oil Leaks from Manual Shaft Oil Seal
No. J7: Oil Leaks from Oil Cooler Pipe Joint

Description:

Oil leaks between engine and converter housing.

Oil leaks between converter housing and main case.

Oil leaks between main case and rear housing.

Oil leaks from oil pan.

Oil leaks from manual shaft oil seal.

Oil leaks from oil cooler pipe joint.

Possible Cause:

Faulty oil seal or sealing of contact surface is considered.

No. Z1: Transmission Overheat

Description:

You smell the transmission burning.

The transmission smokes.

Possible Cause:

Slip of clutch.
If slip of clutch is caused, a DTC (gear ratio error) is stored.

Clogged oil cooler (foreign substance mixed)

ATF stirred excessively (too much ATF).

Faulty torque converter operating pressure.

Faulty lock-up piston.

DIAGNOSIS (JR405E) 7A2-137
No. Z2: Mode Lamp (Power Drive or 3rd Start) Does Not Light Up
When The Power Mode or 3rd Start Mode is Turned On

Description:

The mode lamp on the instrument panel does not light up though the power mode or 3rd start mode is turned on
with the ignition switch in ON position.

Possible Cause:

Faulty mode select switch is considered.

Bulb burn out.


No. Z3: Mode Lamp (Power Drive or 3rd Start) Lights Up When
The Power Mode or 3rd Start Mode is Turned Off

Description:

The mode lamp on the instrument panel lights up though the power mode or 3rd start mode is turned off with the
ignition switch in ON position.

Possible Cause:

Faulty mode select switch is considered.


No. Z4: Oil Temperature Warning Lamp Lights up

Description:

Sometimes, the oil temperature warning lamp lights up.

Possible Cause:

When the vehicle is stuck in the mud or continues to accelerate under overload, and ATF temperature exceeds
145 C, the oil temperature warning lamp lights up.

If the oil temperature warning lamp lights up under usual service condition, following causes are considered.

ATF level has increased for some fault.
Refer to "No. Z1: Transmission overheat".

Lights up due to error of the ATF oil thermo sensor.

No. Z5: Select Lever Feeling is Faulty.

Description:

Select lever feeling is faulty.

Possible Cause:

Disordered select cable.

Disordered select lever.

Faulty Manual plate.

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.