service ISUZU TF SERIES 2004 Workshop Manual

TRANSFER CASE 7D-1

SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service Precaution .......................................................................................................... 7D – 2
General Description ........................................................................................................ 7D – 3
Transfer Rear Oil Seal .................................................................................................... 7D – 4
Transfer Rear Oil Seal and Associated Parts ............................................................ 7D – 4
Removal ........................................................................................................................ 7D – 4
Installation .................................................................................................................... 7D – 4
Transfer Case Assembly ................................................................................................ 7D – 6
Transfer Case Assembly and Associated Parts ........................................................ 7D – 6
Removal ........................................................................................................................ 7D – 7
Installation .................................................................................................................... 7D – 7
Transfer Control Unit ...................................................................................................... 7D – 10
Removal ........................................................................................................................ 7D – 10
Installation .................................................................................................................... 7D – 10
Transfer Disassembly ..................................................................................................... 7D – 11
Removal ........................................................................................................................ 7D – 11
Inspection and Repair .................................................................................................. 7D – 20
Inspection and Repair (Transfer Case Assembly) ..................................................... 7D – 20
Reassembly .................................................................................................................. 7D – 24
Main Data and Specifications ........................................................................................ 7D – 33
Special Tools ................................................................................................................ 7D – 36

7D-2 TRANSFER CASE

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution .................................................................................................... 7D1 - 2
General Description ................................................................................................... 7D1 - 3
System Components ................................................................................................. 7D1 - 5
Parts Location ...................................................................................................... 7D1 - 5
Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11
Parts Location ............................................................................................................ 7D1 - 23
Circuit Diagram .......................................................................................................... 7D1 - 27
Connector List ........................................................................................................... 7D1 - 31
Diagnosis .................................................................................................................... 7D1 - 34
Before determining trouble ................................................................................. 7D1 - 34
Memory erasing procedure ....................................................................................... 7D1 - 40
Diagnosis from symptom .......................................................................................... 7D1 - 41

7D1-2 TRANSFER CONTROL SYSTEM

Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING.
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR
THE SRS COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE
UNNEEDED SRS SYSTEM REPAIRS.

CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)
CONTENTS

Service Precaution .................................................
7A2-2
General Description ...............................................
7A2-2
Electronic Control Diagram ...............................
7A2-3
Transmission Control Module (TCM) (1/2) ......
7A2-4
Transmission Control Module (TCM) (2/2) ......
7A2-5
TCM Point Table .................................................
7A2-6
TCM Voltage & Resistance Check Sheet .......
7A2-7
Control System Diagram ....................................
7A2-9
Control and Functions ........................................
7A2-10
Gear Shift Control 3rd start ...............................
7A2-10
Mode Type ...........................................................
7A2-10
Mode Selection ....................................................
7A2-10
Comparison of mode ..........................................
7A2-11
3rd start Mode .....................................................
7A2-11
Backup Mode .......................................................
7A2-11
Functions of Input / Output Components ........
7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................
7A2-13
High speed CAN bus ..........................................
7A2-13
Diagnosis .................................................................
7A2-13
Electronic Diagnosis ...........................................
7A2-13
Check Trans Indicator ........................................
7A2-13
On Board Diagnostic Check ..............................
7A2-13
"Check Trans" Check .........................................
7A2-14
Tech 2 OBD Connection ....................................
7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............
7A2-30
16 - Terminal Data Link Connector (DLC) ......
7A2-31
Clear DTC ............................................................
7A2-32
DTC Check ..........................................................
7A2-32
TCM Precaution ..................................................
7A2-32
Information On TCM ...........................................
7A2-32
TCM Diagnostic Trouble Codes ........................
7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ...........................................
7A2-34

DTC P0602 (FLASHING CODE 63)
Transmission Control Module (TCM)
Programming Error ................................................
7A2-36
DTC P0705 (FLASHING CODE 17)
Transmission Range Sensor Circuit
Malfunction .............................................................
7A2-38
DTC P0712 (FLASHING CODE 15)
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................
7A2-42
DTC P0713 (FLASHING CODE 16)
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................
7A2-45
DTC P0717 (FLASHING CODE 14)
Input Speed Sensor Signal Error .........................
7A2-48
DTC P0722 (FLASHING CODE 11)
Output Speed Sensor Signal Error .....................
7A2-51
DTC P0743 (FLASHING CODE 33)
Torque Converter Clutch Electrical .....................
7A2-54
DTC P0748 (FLASHING CODE 35)
Pressure Control Solenoid Electrical ..................
7A2-57
DTC P0753 (FLASHING CODE 31)
Shift Solenoid S1 Electrical ..................................
7A2-60
DTC P0758 (FLASHING CODE 32)
Shift Solenoid S2 Electrical ..................................
7A2-63
DTC P1767 (FLASHING CODE 67)
ECM CAN Invalid ...................................................
7A2-66
DTC P1790 (FLASHING CODE 61)
Transmission Control Module ROM
Checksum Error .....................................................
7A2-69
DTC P1791 (FLASHING CODE 62)
Transmission Control Module RAM
Error .........................................................................
7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................
7A2-73

7A2-2 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
General Description
The AW30-40LE is a 4–speed fully automatic
transmission. It uses a microcomputer as a control unit
to judge running conditions including throttle opening
rate and vehicle speed, then it sets the shifting point in
the optimum timing so that best driving performance
can be achieved.
In addition, the built–in shift mode select function can
select three shift modes according to the driver's
preference:
 Normal mode –Normal shift pattern.
 3rd Start mode –Starts in 3rd gear to reduce
slippage on ice or snow.
 Power mode has a delayed up shift when more
powerful acceleration is required.
Also, the built–in fail–safe function (“backup mode")
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the self–diagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of AW30-40LE are as follows:

A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
 Electronic control selects the optimum shift mode according to the driving conditions.
 Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
 Two sets of planetary gears reduce friction of powe
r
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.
 Wide gear ratio and high torque rate of torque
converter provide excellent starting performance.

TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-27

SERVICE PROGRAMMING SYSTEM (SPS)
The procedure to program the control unit by using the
Service Programming System (SPS) software
contained in TIS2000 is explained below.
NOTE:






Should Tech2 display "SPS Procedure was not
successful", engine will not start, but no DTCs
are present, low battery voltage or poo
r
electrical connections should be the primary
suspects. Perform the SPS procedure again
after rectifying the fault/s.


IMPORTANT:
Perform the following checks before attempting to
program the control unit:







The Tech2 PCMCIA card is programmed with
the latest software release.







The latest release of TIS2000 is loaded on the
PC.







The vehicle battery is fully charged.







The control unit to be programmed is
connected to the vehicle.
1. Preparations of TIS 2000
1.
Connect Tech 2 to P/C.
2.
Check to see if Hardware Key is plugged into Port.
3.
Activate TIS 2000 by P/C.
4.
On the activating screen of TIS2000, choose
"Service Programming System"





5.
On the screen of "Diagnostic Tester and
Processing Program Selection", choose the one
that will comply with the following.

Diagnostic tester in use

New programming by the existing module or new
programming by the replaced/new module.

Fixing position of the control unit.
6.
Upon completion of the selection, push the button
of "Continue".

7A2-28 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

2.Demand of Data
1.
Connect Tech-2 to the vehicle. When activated by
turning on the power of Tech-2, push the "Enter"
switch.
2.
Turn on the ignition switch (without starting the
engine)
3.
In the main menu of Diagnostic Tester, push "F1:
Service Programming System (SPS)".
4.
Push "F0: Request Info" of Tech-2.

5.
Where vehicle data has been already saved in
Tech-2, the existing data come on display. In this
instance, as Tech-2 starts asking whether to keep
the data or to continue obtaining anew data from
the control unit, choose either of them.





6.
If you select “continue ”, you have to select “Model
Year ”, “Vehicle Type ”, “Controller Type (Engine) ”.
7.
After that. then push button and turn Ignition
switch tuned on, off, on following Tech-2 display.
Tech-2 will read information from controller afte
r
this procedure.
8.
During obtaining information, Tech-2 is receiving
information from the control unit chosen. In
replacing the control unit, please be sure to
undertake "Obtaining Information" from the new
unit. With VIN not being programmed into the new
control unit at the time of shipment, "obtaining
information" is not complete (because the vehicle
model, engine model and model year are specified
from VIN). For the procedure get additional
information on vehicles, instruction will be
provided in dialog form, when TIS2000 is in
operation.
9.
Following instructions by Tech-2, push the "Exit"
switch of Tech-2, turn off the ignition of the vehicle
and turn off the power of Tech-2, thereby
removing from the vehicle.

3.Data Exchange
1.
Connect Tech-2 to P/C, turn on the power and
click the "Next" button of P/C.
2.
Check VIN of the vehicle and choose "Next".
3.
When a lack of data is asked from among the
following menu, enter accordingly.
Select following Menu

Model Year

Model

Engine type

Transmission type

Destination code (vehicles for general
export)*1

Immobiliser
* 1: How to read the destination code
"Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
Fig.-3, the destination code can be read as "EK4"
(Europe).

TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-29





4.
After choosing the data, click the "Next" button.
5.
When all the necessary information is entered, the
"details" of software within the database that
match the entered data will appear fo
r
confirmation. Click the "Program" switch and then
download the new software onto Tech-2.
6. "Data Transfer" comes on display. The progress o
f
downloading will be displayed on the screen in the
form of bar graph.
7.
Upon finishing the data transfer, turn off the powe
r
of Tech-2, removing from P/C.


4. Programming of ECM 1.
Check to see if batteries are fully charged, while
ABS connectors shall be removed from the
vehicle.
2.
Connect Tech-2 to Vehicle Diagnostic Connectors.
3.
Turn on the power of Tech-2 and the title screen
comes on display.
4.
Turn on the ignition (without allowing the engine to
start)
5.
On the title screen of Tech-2, push the "Enter"
button.
6.
Choose "F: Service Programming System" on the
main screen and then choose "Fl: Programming".
7.
While data is being transferred, "Downloading"
will be displayed on the Tech-2 screen.
8.
Upon finishing the data transfer, Tech-2 will
display "Reprogramming Successful". Push the
"Exit" button to bring program to completion.

9.
Following "Procedure 2: Demand of Data", try ove
r
again "Information Obtaining" and check to
confirm if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition o
f
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-37

DTC P0602 (FLASHING CODE 63) Transmission Control Module (TCM)
Programming Error
Circuit Description
The Service Programming System (SPS) updates the
flash calibration files that are stored in a Transmission
Control Module (TCM). The calibration file
custom-tailors a module to a certain vehicle. The
calibration file contains data for things such as spark
curves and fuel control. When troubleshooting a
driveability problem, diagnosis may call fo
r
reprogramming the controller with newer calibration
information to correct a customer concern and Vehicle
Identification Number (VIN).
Condition for setting the DTC
When the TCM is not written VIN No.
Action Taken When The DTC Sets

DTC stored.
Conditions For Clearing The DTC

The DTC can be cleared from the TCM history by
using a scan tool.
 The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.

After more than 1 second has elapsed after the
ignition key has been turned “ON", short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
DTC P0602 is indicated when the TCM does not written
VIN No. A security lock is performed by SPS. And not
replace the TCM when DTC P0602 can repair by SPS.