transmission ISUZU TF SERIES 2004 Workshop Manual

7A3-32 ON-VEHICLE SERVICE (AW30 –40LE)

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.




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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 select
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 select
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.

7A3-34 ON-VEHICLE SERVICE (AW30 –40LE)

Transmission Control Module (TCM)


RTW37ALF001801
Removal
Preparation:
Disconnect negative ( –) battery cable.
1. Disconnect the TCM harness connectors.
2. Remove fixing nuts (2 pieces) and TCM with bracket from the car.
NOTE: The TCM is fitted under instrument panel of the
driver's compartment by means of two stud bolts.
3. Remove fixing nuts (2 pieces) and remove TCM
from bracket.


Installation
To install, follow the removal steps in reverse order.

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



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9. Remove the oil strainer assembly.



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7A3-36 ON-VEHICLE SERVICE (AW30 –40LE)

10.Disconnect the solenoid wiring connectors from the
shift solenoid S1(1), S2(2), lock-up solenoid(3) and
pressure control solenoid(4).



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11. Remove each retaining bolts and solenoids. (Except
pressure control solenoid:)
Pressure control solenoid cannot be removed.
Installation
To install, follow the removal steps in reverse order
noting the following point;
Refer to the section Reassembly of Majo
r
Components(2) and Transmission Removal an
d
Installation .
Torque:
Solenoid S1, S2 bolt – 7 N m (61 Ib in)
Lock-up solenoid bolt – 10 N m (87 Ib in)

7A3-38 ON-VEHICLE SERVICE (AW30 –40LE)

2. Remove the oil strainer assembly.




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3. Disconnect the solenoid wiring connectors from the
solenoids.
4. Remove the twenty bolts from the valve body.
5. Remove the valve body assembly and pressure control solenoid.

After removing valve body assembly from the
transmission case, loosen the solenoid clamp
bolt and remove the pressure control solenoid
from the upper valve body assembly.
Also disconnect the harness connector from the
pressure control solenoid.

NOTE:

Two or more persons are required for removal and
installation of the valve body assembly and pressure
control solenoid.
 The check valve assembly (1) and the C0
accumulator piston springs (2) will fall from the
transmission case during removal of valve bod
y
assembly.
Protect these parts from damage. The B0 (3), C2 (4),
and B2 (5) accumulator piston and springs may also
fall free and must be protected.



244RY00018







244RY00006

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-39

Installation
To install, follow the removal steps in reverse order
noting the following point;
1. Reinstall the parts removed with the valve bod
y
assembly to their assigned positions in the
transmission case (check valve assembly, C0
accumulator pistons, etc). Install the valve bod
y
assembly to the transmission case.
Refer to REASSEMBLY OF MAJO
R
COMPONENTS (2).
2. Solenoid clamp bolt
Torque : 7 N 


m (61 Ib in)
3. Valve body fixing bolts
Each bolt location and length (mm) is indicated in
the figure.
Torque : 10 N 


m (87 Ib in)
NOTE: Tighten the bolts toward outside equally.




244R200078
4. Oil strainer fixing bolts
Torque : 10 N 


m (87 Ib in)
5. Oil pan fixing bolts
Torque : 8 N 


m (69 Ib in)

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

Rear Oil Seal (Adapter Housing, 4
 
4)

Removal

1. Remove the front and rear propeller shaft assembly
from the transfer case.
2. Remove the transfer case assembly from the transmission case.
Refer to Section 4 DRIVELINE/AXLE.
3. Using a screwdriver, remove the rear oil seal.
Installation
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the adapter housing.
Oil seal installer : J –36797



RUW37ASH002401
3. Install the transfer case assembly.
Refer to section 4 DRIVE/AXLE.
4. Install the front and rear propeller shaft assembly.
Torque (Propeller shaft flange bolt) : 63 N 


m (46
Ib ft)

7A3-42 ON-VEHICLE SERVICE (AW30 –40LE)

Transmission Assembly
Transmission and Associated Parts




Legend
(9) Under Cover
(1) Rear Propeller Shaft (10) Flex Plate Torque Converter bolt
(2) Front Propeller Shaft (4WD only) (11) Shift Cable
(3) Middle Exhaust Pipe (12) Rear Mount Rubber
(4) Transfer Case Assembly (4WD only) (13) Heat Protector
(5) Fuel Pipe Clip and Bracket (14) Transmission Crossmember
(6) ATF Pipe and Clip (15) Transmission Assembly (2WD)
(7) Oil Level Gauge and Guide Tube (16) Transmission Assembly (4WD)
(8) Suspension Crossmember

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-43

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands.
3. Remove front propeller shaft.(4WD only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
5. Remove the middle exhaust pipe.



RTW37ASH0001

6. Disconnect the transfer harness connectors and the
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
7. Support transfer case with a transmission jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.






P1010010
11. Discinnect the transmission harness connectors
and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.

7A3-44 ON-VEHICLE SERVICE (AW30 –40LE)

14. Remove the under covers.





P1010012
15. Remove the flex plate torque converter bolts by
turning the crank shaft.





P1010005

16. Remove the heat protector and the fuel pipe clips
with fuel pipes on the transmission crossmember.





P1010005B
17.Disconnect the ATF pipes.
18. Remove the ATF pipe clips.




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