manual transmission ISUZU TF SERIES 2004 Workshop Manual

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) 7A3-13
SHIFT CABLE




RTW47ALF000201
Legend
1. Select lever
2. Select lever base
3. Shift cable
4. Bracket

5. Adjuster
6. Manual shaft select lever
7. Shift cable retaining pawl
8. Clip

Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Move the select lever to the “N” position.
4. Remove the rear console and front console.
5. Disconnect the shift cable from the select lever.
6. Press on the shift cable retaining pawl to remove the
cable from the select lever base.

7. Disconnect the shift cable from the transmission
side.
8. Remove the shift cable from the bracket.
9. Pull the shift cable free from the bottom of the
vehicle.

7A3-14 ON-VEHICLE SERVICE (JR405E)
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the “N” position.
6. Check that the transmission is in the “N” position.
249R300002
7. Slide the cover in the direction shown by the arrow
(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.
P1010012

9. Connect the shift cable to the manual shaft selec
t
lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.
P1010016-2
11. Press the select lever knob button 5 times.
Then check that the select lever moves smoothly to
each of its positions.
13. Check that the shift position indicated by the selec
t
lever and the actual shift position are the same.
14. Install the front console and rear console.
15. Connect the negative battery cable.
16. 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.

7A4-54 UNIT REPAIR (JR405E)

TRANSMISSION CASE

02CASE-BK06
Legend
1. Transmission case
2. Spring pin (slender)
3. Spring pin (fat)
4. Manual plate
5. Detent spring


6. Parking rod
7. Manual shaft
8. Oil seal
9. Inhibitor switch

7A4-58 UNIT REPAIR (JR405E)
Free length = 22.3 mm (0.878 in)
Linear diameter = 1.1 mm (0.043 in)


12CASE-AY06

Reassembly steps
1. Oil seal, manual shaft, and manual plate

Use the oil seal installer to force the manual plate oil
seal into place.
Oil seal installer: 5-8840-2758-0


14CASE-AY21



Install the manual shaft together with the manual plate.


15CASE-AY26



Drive the spring pin into the transmission case.


16CASE-AY37

2. Parking rod

Rotate the manual plate while installing the parking rod.

UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43



Use a pin punch to drive the manual plate spring pin into
place.


21CASE-AY48

3. Detent spring

Install the detent spring and tighten the fixing bolt to the
specified torque.
Torque: 7 N






m (61 Ib






in)


23CASE-AY53

4. Harness assembly

Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.

Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
Torque: 6 N






m (52 Ib






in)


24ASSY003

5. Low one-way clutch inner race

Install new seal rings to the low one-way clutch inne
r
race.


25ASSY126



Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0004~0.001 in)

UNIT REPAIR (JR405E) 7A4-81

43ASSY119

20.Control valve assembly


Align the manual valve and the manual plate of the
transmission case.











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

44ASSY121


Torque: 8 N 


m (69 Ib 


in)



45CV29



Connect the harness assembly and control valve
assembly connectors.

7A4-82 UNIT REPAIR (JR405E)
244L300001


21.Oil pan

Install a new gasket and the oil pan.

Tighten the bolts to the specified torque.
Torque: 8 N 


m (69 Ib 


in)

47INH-SW01

22.Inhibitor switch

Secure the inhibitor switch (1) by hand-tightening the 2
bolts.

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.

Tighten the 2 inhibitor switch bolts to the specified
torque.