battery ISUZU TF SERIES 2004 Workshop Manual

7A2-154 DIAGNOSIS (JR405E)
TCM VOLTAGE CHECK




TCM voltage check is done to check for transmission and TCM
problems which cannot be detected by self-diagnosis.
Additionally, it severs as a back-up check for self-diagnosis.
Measure the voltage drop and make a continuity test for each of
sensors, solenoids and switches.
If the voltage is within the specified range and continuity exists,
that particular area of the TCM and transmission assembly is
normal.
If voltage deviation or lack of continuity is discovered, disconnect
the applicable parts and check of them individually.

Inspection Tool
Use a circuit tester and an oscilloscope to measure voltage and
circuit continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.

TCM Pin Assignment












         
 






 




      













 








Connect to White Connector Connect to Grey Connector


No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
A1 RED V BATT (Battery Back-up Power
Supply) Input Battery Voltage - 10 – 14.5V Related
harness
At P range 10 – 14.5V Related
harness
A2 YEL/
VIO P Range Switch Input Inhibitor switch Voltage
At other than
P range Less than 2VInhibitor
switch
At brake
stepped 10 – 14.5V Related
harness
A3 RED Brake Switch Input Brake switch Voltage At brake no
stepped Less than 2V Brake switch
At lamp OFF 10 – 14.5V Related
harness A4 PNK/
WHT 3rd Start Indicator Lamp Output 3rd start lamp Voltage
At lamp ON Less than 2V Lamp
A5 GRN K-line signal (Tech 2 serial
communication) Input/
OutputTech 2 - - - Related
harness
A6 - - - - - - - -

7A3-4 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION CONTROL MODULE (TCM)



RTW37ALF001901

Remove and Disconnect
1. Disconnect the negative battery cable.
2. Remove the connectors.
3. Remove the fixing nuts and remove the TCM (1)
from the bracket.
Note:
The TCM is fitted under instrument panel of the driver’s
compartment by means of three stud bolts.


Install or Connect
Follow the removal steps in the reverse order. Be
absolutely sure that the connectors are securely
fastened.
AT CONT

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

7A3-10 ON-VEHICLE SERVICE (JR405E)
SELECT LEVER
RTW37ALF001101
Legend
1. Rear console
2. Front console
3. Select lever knob
4. Upper housing
5 Lamp assembly

6 Base plate
7 Grooved pin
8 Spring plate
9 Lever assembly
10 Sleeve


Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Remove the rear console and the front console.
4. Remove the 2 screws fixing the select lever knob.
5. Remove the knob together with the knob button and
spring from the lever.
6. Turn the sleeve counterclockwise to remove it. Make
a note of the number of turns required to free the
sleeve.
7. Remove the harness connectors from the base plate.
8. Remove the upper housing (held in place by 4
latched fasteners).
9. Remove the spring plate.

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) 7A3-17
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.

7A3-18 ON-VEHICLE SERVICE (JR405E)
CONTROL VALVE ASSEMBLY
244L300001
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. Disconnect the 2 harness connectors leading to the
control valve.
7. Remove the 12 bolts and the control valve assembly.
Number of bolts Length
10 (A)
2 (B) 40 mm (1.57 in)
30 mm (1.18 in)

Note:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the
valve from turning).