service ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-51


Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter
Inside/Outside Rear Race Diameter
Inside/Outside
1 28.6 (1.13) / 46.5 (1.83) 28.9 (1.14) / 50.2 (1.98) —
2 28.45 (1.12) / 47.23 (1.86) 29.1 (1.15) / 50.2 (1.98) —
3 24.7 (0.97) / 41.8 (1.65) 24.2 (0.95) / 47.8 (1.88) —
4 37.2 (1.46) / 58.8 (2.31) 33.7 (1.33) / 50.1 (1.97) —
5 36.7 (1.44) / 50.85 (2.00) 33.7 (1.33) / 47.8 (1.88) —
6 26.0 (1.02) / 48.9 (1.93) 26.0 (1.02) / 46.7 (1.84) 26.8 (1.06) / 47.0 (1.85)
7 — 35.15 (1.38) / 53.65 (2.11) 34.3 (1.35) / 47.8 (1.88)
8 33.7 (1.33) / 47.6 (1.87) 35.6 (1.40) / 47.7 (1.88) —
9 28.5 (1.12) / 44.2 (1.74) 27.7 (1.09) / 44.2 (1.74) —
10 — 39.38 (1.55) / 58.15 (2.29) —

7A3-52 ON-VEHICLE SERVICE (AW30 –40LE)

MEMO

DIAGNOSIS (JR405E) 7A2-1
SECTION 7A2
DIAGNOSIS
TABLE OF CONTENTS
PAGE
BASIC TROUBLE SHOOTING..................................................................................................7A2-6
CHECK TRANS INDICATOR & SELF DIAGNOSIS..............................................................7A2-7
DIAGNOSIS WITH TECH 2........................................................................................................7A2-9
TECH 2 CONNECTION .................................................................................................. 7A2-9
TECH 2 OPERATING FLOW CHART (START UP)..............................................................7A2-10
TYPICAL SCAN DATA................................................................................................................7A2-13
MISCELLANEOUS TEST...........................................................................................................7A2-14
INTERMITTENT DIAGNOSIS....................................................................................................7A2-16
SNAPSHOT DISPLAY WITH TIS 2000....................................................................................7A2-17
SERVICE PROGRAMMING SYSTEM (SPS) ................................................................. 7A2-21
CIRCUIT DIAGRAM.....................................................................................................................7A2-24
PART LOCATION........................................................................................................................7A2-26
CONNECTOR LIST.....................................................................................................................7A2-31
DIAGNOSIS TROUBLE CODE TABLE...................................................................................7A2-33
FAIL-SAFE FUNCTION..............................................................................................................7A2-35
DTC P0722 (FLASH CODE 11) VEHICLE SPEED SENSOR NO SIGNAL......................7A2-36
DTC P0727 (FLASH CODE 13) ENGINE REVOLUTION SENSOR NO SIGNAL............7A2-38
DTC P0717 (FLASH CODE 14) TURBINE SPEED SENSOR NO SIGNAL......................7A2-40
DTC P0710 (FLASH CODE 15) ATF TEMPERATURE SENSOR FAILURE....................7A2-42
DTC P0560 (FLASH CODE 16) SYSTEM VOLTAGE FAILURE........................................7A2-43
DTC P0705 (FLASH CODE 17) INHIBITOR SWITCH FAILURE........................................7A2-44
DTC P1120 (FLASH CODE 22) THROTTLE SIGNAL FAILURE........................................7A2-46
DTC P1875 (FLASH CODE 25) GND RETURN CIRCUIT FAILURE.................................7A2-47
DTC P0753 (FLASH CODE 31) LOW & REVERSE BRAKE DUTY
SOLENOID FAILURE................................................................................................................7A2-48
DTC P0758 (FLASH CODE 32) 2-4 BRAKE DUTY SOLENOID FAILURE......................7A2-51
DTC P0763 (FLASH CODE 33) HIGH CLUTCH DUTY SOLENOID FAILURE................7A2-54
DTC P0768 (FLASH CODE 34) LOW CLUTCH DUTY SOLENOID FAILURE................7A2-57

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

DIAGNOSIS (JR405E) 7A2-21
SERVICE PROGRAMMING SYSTEM (SPS)
The procedure to program the control unit by using Service Programming System (SPS) software contained in TIS
2000 is explained in steps below.

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







The Tech 2 PCMCIA card is programmed with the latest software release.







The latest release of TIS2000 is located 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 Tech2 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 "Next".


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.

7A2-22 DIAGNOSIS (JR405E)


6. If you select “continue”, you have to select “Model Year”, “Vehicle Type”.
7. After that, push button and turn Ignition switch tuned on, off, on following Tech-2 display. Tech-2 will read
information from controller after this procedure.
8. During obtaining information, Tech-2 is receiving information from the control unit ECM and TCM at the same
time. 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. Select “Transmission” in the “System Type” selection.
4. When a lack of data is asked from among the following menu, enter accordingly.
Select following Menu

Model Year

Model

Engine type

Destination code (vehicles for general export)*1

* 1: How to read the destination code:
Destination code can be read from service ID Plate affixed on vehicle, while on service ID Plate the destination
code is described at the right-hand edge of Body Type line. In the figure, the destination code can be read as "RR3"
for Australia.

DIAGNOSIS (JR405E) 7A2-23


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 for confirmation. Click the "Program" switch and then download the new software
onto Tech-2.
6. "Data Transfer" comes on display. The progress of downloading will be displayed on the screen in the form of
bar graph.
7. Upon finishing the data transfer, turn off the power of Tech-2, removing from P/C.


4. Programming of TCM
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 "F1: Service Programming System" on the main screen and then choose "F1: Programming ECU".
7. While data is being transferred, "Programming in Progress" will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display "Reprogramming was Successful". Push the "Exit" button
to bring program to completion.
9. Following "Procedure 2: Demand of Data", try over again "Information Obtaining" and check to confirm if the
data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of the vehicle and then turn off the power of Tech-2,
removing from the vehicle.

DIAGNOSIS (JR405E) 7A2-67
Step Action Yes No
9 Check if the trouble is caused by a poor connection of terminal
assembly connector.
With the key switch in OFF position, is the connection condition of
the connector and harness correct?
Go to Step 10
Repair the harness
or connector.
Go to Step 12
10 Remove the oil pan. Is the continuity correct between terminal
assembly terminal 12 and low & reverse brake pressure switch
connector?

12
Go to Step 11
Repair the harness
or connector.
Go to Step 12
11 Is the result OK when the oil pan is removed and the low & reverse
brake pressure switch is checked? Refer the ON VEHICLE
SERVICE SECTION in this manual for the procedure. Repair the control
valve.
Go to Step 12
Replace pressure
switch.
Go to Step 12
12 Clear the DTC from the memory and perform the work after repair. Is
the same DTC code outputted again in the subsequent DTC check?
Replace the TCM Go to Step 13
13 Are the other DTCs outputted? Go to Other DTC
Section Action is completed

7A2-82 DIAGNOSIS (JR405E)
DTC P0602 Programming Error

Setting Condition:

When reprogramming operation is stopped under Service Programming System (SPS).

When non programmed TCM (blank TCM) is used without Service Programming System (SPS).

Fail Safe:

Lock-up is inhibited.

All solenoid operations stop (OFF) and the gear is fixed to the 3rd.

Possible Cause:

Low battery voltage while Service Programming System (SPS) is operated.

No programmed TCM (blank TCM) is used.

Recover DTC:
Reprogram the TCM using with Service Programming System (SPS).

DIAGNOSIS (JR405E) 7A2-137
No. Z2: Mode Lamp (Power Drive or 3rd Start) Does Not Light Up
When The Power Mode or 3rd Start Mode is Turned On

Description:

The mode lamp on the instrument panel does not light up though the power mode or 3rd start mode is turned on
with the ignition switch in ON position.

Possible Cause:

Faulty mode select switch is considered.

Bulb burn out.


No. Z3: Mode Lamp (Power Drive or 3rd Start) Lights Up When
The Power Mode or 3rd Start Mode is Turned Off

Description:

The mode lamp on the instrument panel lights up though the power mode or 3rd start mode is turned off with the
ignition switch in ON position.

Possible Cause:

Faulty mode select switch is considered.


No. Z4: Oil Temperature Warning Lamp Lights up

Description:

Sometimes, the oil temperature warning lamp lights up.

Possible Cause:

When the vehicle is stuck in the mud or continues to accelerate under overload, and ATF temperature exceeds
145 C, the oil temperature warning lamp lights up.

If the oil temperature warning lamp lights up under usual service condition, following causes are considered.

ATF level has increased for some fault.
Refer to "No. Z1: Transmission overheat".

Lights up due to error of the ATF oil thermo sensor.

No. Z5: Select Lever Feeling is Faulty.

Description:

Select lever feeling is faulty.

Possible Cause:

Disordered select cable.

Disordered select lever.

Faulty Manual plate.