transmission fluid ISUZU TF SERIES 2004 Owner's Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-35

Shift Solenoid and Lock-Up Solenoid
Removal
Preparation:

Disconnect negative ( –) battery cable.
 Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove oil lever gage and oil filler tube.
2. Support transfer case (4
4) or rear cover (42)
with a transmission jack.
3. Remove engine rear mounting nuts.


F07RW008
4. Remove fule pipe heat protector on tansmission
corssmenber.
5. Remove fuel pipe from the crossmenber.
6. Remove transmission crossmenber.
7. Remove the nineteen bolts.
8. Remove oil pan, using seal cutter J –37228.



RUW37ASH002901

NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J –37228
Examine particles in oil pan
Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type o
f
wear you will find in the transmission:
Steel (magnetic) ..................bearing, gear and
clutch plate wear
Brass (non-magnetic) ..........bushing wear



240RY00008
9. Remove the oil strainer assembly.



244RY00003

7A3-50 ON-VEHICLE SERVICE (AW30 –40LE)

Major Components
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component
group during assembly, inspect and repair this group
immediately.
General Assembly Notes:
1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful
inspection before assembly because even a small
nick could cause fluid leakage or affect
performance.


2. Before assembling new clutch discs and brake
bands, soak them in automatic transmission fluid fo
r
at least thirty minutes.
3.
Apply automatic transmission fluid on the sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in thei
r
palces.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.



Bearing and Race

RUW36AM F000201

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

7A1-8 CONSTRUCTION AND FUNCTION
STRUCTURE AND FUNCTION OF COMPONENT
TORQUE CONVERTER (WITH LOCK-UP FUNCTION)

The torque converter is a device for transmitting the engine torque to the transmission. It transmits power
by means of oil when the lock-up is disengaged and by means of a lock-up piston when it is engaged.

The torque converter is of the symmetrical, three-element, single-stage, two-phase type.

As shown in the drawing, the symmetrical three-elements refer to three elements (components) consisting
of impeller (1), turbine (2) and stator (3) that are arranged symmetrically (figure 5).

"Single-stage" means that there is only one turbine as an output element; "two-phase" means that the
pump impeller acts as a torque converter when the turbine speed is comparatively low, and as a fluid
coupling when the speed is high.


















1. Pump Impeller
2. Turbine Runner
3. Stator














1. Pump Impeller
2. Turbine Runner
3. Stator
4. Converter Cover
5. One-way Clutch
6. Lock-up Piston
7. Torsion Damper

Figure 5. Torque Converter
Figure 6. Construction of Torque Converter

Lock-up mechanism

"Lock-up" refers to a fixed state of the lock-up piston inside the torque converter and thus connects the
engine directly to the transmission.

The hydraulic pressure for the lock-up control is supplied from two circuits.

When the lock-up is disengaged (Figure 7)

When the lock-up is disengaged, the torque converter operating pressure is supplied from the oil passage
(A) to between the cover and the lock-up piston, and separates the lock-up piston clutch facing and
converter cover.

As a result, the engine drive power is transmitted from the converter cover to the pump impeller, the ATF
and to the turbine. The torque converter function as a fluid connector in this condition.

The torque converter operating pressure is supplied from the oil passage (A), passes through the oil
passage (B).

When the lock-up is engaged (Figure 8)

When the lock-up is engaged, the torque converter operating pressure is supplied from oil passage (B) to
the oil pump impeller, turbine, then to the stator side. The oil between the lock-up piston and converter
cover is drained.

Since the force acting on the right side of the lock-up piston is greater than force on the left side, it
connects the lock-up piston clutch facing with the converter cover, thereby increasing the transmission
efficiency.

7A2-6 DIAGNOSIS (JR405E)
BASIC TROUBLE SHOOTING

Transmission fluid pressure together with clutch and brake friction and other important transmission functions are
controlled by electrical signal from the Transmission Control Module (TCM).
Random diagnosis can produce inaccurate and misleading indications. It is important that diagnosing procedure be
carried out systematically.
Carefully follow the sequence outlined below to diagnose automatic transmission assembly.




Verify Customer Complain
Preliminary Check
(Visual Check/Test Drive)
Compare to Same Model
(If Available)
Check Service Bulletin
DTC Check
(Self-diagnosis/Tech 2)
Go to Symptom Diagnosis
Stall Test
Line Pressure Test
Transmission Overhaul
Repair & Verify Fix
Transmission Overhaul
Transmission Overhaul
Go to DTC Chart
Go to Intermittent Diagnosis NG
Follow the instructions
NG
No Instruction
NG
OK
NO DTC
Not Solved
OK
OK
Follow the Bulletin
(Once Clear Memory) Restored
Not Stored
Use Service Programming
System (SPS)
Not Solved

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20

7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.



AUTOMATIC TRANSMISSION FLUID (ATF)
Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch band
and other parts.
The transmission control module, the transmission unit,
and the vehicle must be carefully checked if gum or
varnish is present.




ATF LEVEL
Inspect
Hot Level
1. Warm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80
C (176
F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each gear range just long enough for the
transmission to engage.
5. Return the select lever to either “P” or “N”.
C07RW009
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 “H” range on the
dipstick.
242R300001
If the ATF level is below the “H” range, ATF must be
added.

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.

ON-VEHICLE SERVICE (JR405E) 7A3-21
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.
6. Loosen (do not remove) the nuts securing the
exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the
transmission.
8. Remove the fuel pipe bracket.
P1010013

P1010014
9. Remove the ATF level dipstick and tube.
10. Remove the undercover.
11. Rotate the ring gear and remove the 6 torque
converter bolts.
P1010016
12. Remove the automatic transmission fluid cooling
pipe.
P1010060
13. Place a jack beneath the engine to support it.
14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the
engine and transmission. Do not allow the radiato
r
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the
engine.
18. Lower the transmission from beneath the vehicle.
Take care not to damage the breathers.

Install or Connect
1. Install the transmission to the engine and tighten the
bolts.
Bolt torque : M10 40 N·m (30 lb·ft)
M12 76 N·m (56 lb·ft)
2. Install the cable bracket to the transmission.
3. Connect the engine harness connectors.

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