content ISUZU TF SERIES 2004 Manual PDF

3C-8 FRONT SUSPENSION


FRONT SUSPENSION
(4




2 Except High Ride Suspension)
CONTENTS

Service Precaution............................................. 3C-8
Shock Absorber ................................................. 3C-9
Shock Absorber and Associated Parts ........... 3C-9
Removal ......................................................... 3C-9
Installation....................................................... 3C-10
Shock Absorber with Coil Spring .................... 3C-12
Stabilizer Bar ..................................................... 3C-15
Stabilizer Bar and Associated Parts ............... 3C-15
Removal ......................................................... 3C-15
Inspection and Repair..................................... 3C-15
Installation....................................................... 3C-16
Knuckle .............................................................. 3C-17
Knuckle and Associated Parts........................ 3C-17
Removal ......................................................... 3C-17
Inspection and Repair..................................... 3C-18
Installation....................................................... 3C-18
Upper Control Arm ............................................. 3C-19
Upper Control Arm and Associated Parts ...... 3C-19
Removal ......................................................... 3C-19
Inspection and Repair..................................... 3C-20
Installation....................................................... 3C-20

Lower Control Arm ............................................. 3C-21
Lower Control Arm and Associated Parts ...... 3C-21
Removal ......................................................... 3C-21
Inspection and Repair..................................... 3C-22
Installation ...................................................... 3C-22
Upper Ball Joint ................................................. 3C-23
Upper Ball Joint and Associated Parts ........... 3C-23
Removal ......................................................... 3C-23
Inspection and Repair..................................... 3C-24
Installation ...................................................... 3C-24
Lower Ball Joint ................................................. 3C-25
Lower Ball Joint and Associated Parts ........... 3C-25
Removal ......................................................... 3C-25
Inspection and Repair..................................... 3C-26
Installation ...................................................... 3C-26
Bump Rubber .................................................... 3C-27
Bump Rubber Joint and Associated Parts...... 3C-27
Removal ......................................................... 3C-27
Inspection and Repair..................................... 3C-27
Installation ...................................................... 3C-27
Special Tools .................................................. 3C-28

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.

3C-30 FRONT SUSPENSION


FRONT SUSPENSION
(4





2 High Ride Suspension, 4





4)
CONTENTS

Service Precaution............................................. 3C - 29
Shock Absorber ................................................. 3C - 30
Shock Absorber and Associated Parts ........... 3C - 30
Removal ......................................................... 3C - 30
Inspection and Repair..................................... 3C - 30
Installation....................................................... 3C - 30
Stabilizer Bar ..................................................... 3C - 31
Stabilizer Bar and Associated Parts ............... 3C - 31
Removal ......................................................... 3C - 31
Inspection and Repair..................................... 3C - 31
Installation....................................................... 3C - 32
Torsion Bar ........................................................ 3C - 33
Torsion Bar and Associated Parts .................. 3C - 33
Removal ......................................................... 3C - 33
Inspection and Repair..................................... 3C - 34
Installation....................................................... 3C - 34
Knuckle .............................................................. 3C - 36
Knuckle and Associated Parts........................ 3C - 36
Removal ......................................................... 3C - 36
Inspection and Repair..................................... 3C - 38
Installation....................................................... 3C - 38
Upper Control Arm ............................................. 3C - 39
Upper Control Arm and Associated Parts ...... 3C - 39
Removal ......................................................... 3C - 39

Inspection and Repair..................................... 3C - 40
Installation ...................................................... 3C - 41
Lower Control Arm ............................................. 3C - 43
Lower Control Arm and Associated Parts ...... 3C - 43
Removal ......................................................... 3C - 44
Inspection and Repair..................................... 3C - 45
Installation ...................................................... 3C - 45
Upper Ball Joint ................................................. 3C - 47
Upper Ball Joint and Associated Parts ........... 3C - 47
Removal ......................................................... 3C - 47
Inspection and Repair..................................... 3C - 48
Installation ...................................................... 3C - 48
Lower Ball Joint ................................................. 3C - 49
Lower Ball Joint and Associated Parts ........... 3C - 49
Removal ......................................................... 3C - 49
Inspection and Repair..................................... 3C - 50
Installation ...................................................... 3C - 50
Bump Rubber .................................................... 3C - 51
Bump Rubber and Associated Parts .............. 3C - 51
Removal ......................................................... 3C - 51
Inspection and Repair..................................... 3C - 51
Installation ...................................................... 3C - 51
Special Tools .................................................... 3C - 52



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 o
r
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.

REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications...........................................................................................3D- 2
Torque Specifications........................................................................................................ 3D- 3
Rear Suspension................................................................................................................3D- 4
General Description ...................................................................................................... 3D- 4
Leaf Spring and Shock Absorber ..................................................................................... 3D- 5
Leaf Spring and Associated Parts ............................................................................... 3D- 5
Removal .........................................................................................................................3D- 6
Inspection and Repair ................................................................................................... 3D- 7
Installation ..................................................................................................................... 3D- 8
Leaf Spring Assembly ....................................................................................................... 3D- 9
Disassembly .................................................................................................................. 3D- 9
Inspection and Repair ................................................................................................... 3D- 9
Reassembly ................................................................................................................... 3D- 10
Troubleshooting................................................................................................................. 3D- 11

WHEELS AND TIRES 3E-1

SECTION 3E
WHEELS AND TIRES
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3E- 2
Torque Specifications ....................................................................................................... 3E- 3
Special Parts Fixing Nuts and Bolts ............................................................................ 3E- 3
Wheels and Tires ...............................................................................................................3E- 4
General Description ...................................................................................................... 3E- 4
Servicing ........................................................................................................................ 3E- 6
Disassembly and Reassembly ..................................................................................... 3E- 7
Inspection and Repair................................................................................................... 3E- 8
Troubleshooting ................................................................................................................3E- 10

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

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

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

TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-13

CAN bus systems in automatic
transmission control (AW30-40LE)
The automatic transmission control system in AW30-
40LE uses high speed CAN bus system .The individual
CAN bus systems are connected via two interfaces and
can exchange information and data. This allows control
modules that are connected to different CAN bus
systems to communicate.
High speed CAN bus
Transmission control modules in the vehicle that require
continuous, rapid communication are connected to the
high speed CAN bus. For example, the automatic
transmission is continuously notified of the current
engine load status. Since the automatic transmission
control module has to react immediately to load status
changes, rapid communication is required between the
engine control module and the automatic transmission
control module. The high speed CAN bus in the AW30-
40LE is designed as a two-wire CAN bus (twisted pair).
The wires are shielded and twisted. The transfer rate is
500 K baud.




RUW37ASF000401
Diagnosis
Electronic Diagnosis
How To Diagnose The Problem
1. To avoid incorrect diagnostics, this book needs to
be followed accurately. Unless stated, do not jump
directly to a section that could contain the
solution. Some important information may be
missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The go to “
SECTION"
means to continue to check
going to the “section".
4. The go through “
SECTION"
means to go through
the “section" and then to go back to the place the
go through was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory o
f
electricity. This includes the meaning of voltage,
amps, ohms, and what happens in a circuit with an
open or shorted wire. You should also be able to
read and understand wiring diagrams.
Check Trans Indicator
Find CHECK TRANS indicator and verify if it is
A. Flashing: Go to DIAGNOSTIC CHECK.
B. Staying on: Go through CHECK TRANS CHECK
.
C. Is never ON when the ignition key is turned on: Go through CHECK TRANS CHECK
D. Is ON during 3 seconds at ignition but OFF after: Normal operation. No DTC or malfunction.



RTW37ASH000401
On Board Diagnostic Check
This test determines if the transmission or its input or
output connections or sensors are failing.
1. Connect the Tech 2: Go through Tech 2 OBD
CONNECTION .
2. Turn on the ignition but not the engine.
3. Push “F0" on Tech 2 to see the Diagnostic Trouble
Code (DTC):

ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
TRANSMISSION
ON-VEHICLE SERVICE (AW30–40LE)
CONTENTS

Service Precaution .................................................
7A3-2
Location of Clutch, Brake, One-Way Clutch
and Solenoid ........................................................
7A3-3
Operation of Clutch, Brake and One-Way
Clutch ....................................................................
7A3-4
Trnasmission Indentification ..............................
7A3-4
Speed Change and Lock-Up Pattern ...............
7A3-5
Overdrive and Lock-Up Operating
Conditions ............................................................
7A3-5
Diagnosis .................................................................
7A3-6
Basic Troubleshooting ........................................
7A3-6
Manual Shifting Test ...........................................
7A3-12
Stall Test ..............................................................
7A3-12
Time Lag Test .....................................................
7A3-13
Hydraulic Test ......................................................
7A3-14
Road Test .............................................................
7A3-15
Shift Pont Chart and Lock-Up Point Chart ..........
7A3-19
Shift Pont Chart ...................................................
7A3-19
Lock-Up Point Chart ...........................................
7A3-20
Transmission Fluid Level and Condition .............
7A3-21
Inspection .............................................................
7A3-21
ATF Replacement ..................................................
7A3-22
Inspection .............................................................
7A3-22
Neutral Start Switch (Mode Switch) .....................
7A3-23
Inspection .............................................................
7A3-23
Removal ...............................................................
7A3-23
Installation ............................................................
7A3-23
Brake Signal ............................................................
7A3-24
Inspection .............................................................
7A3-24
Input and Output Revolution Sensor ....................
7A3-25
Inspection .............................................................
7A3-25
Pattern Select Switch .............................................
7A3-25
Inspection .............................................................
7A3-25
Solenoid ...................................................................
7A3-26
Inspection .............................................................
7A3-26

ATF Temperature Sensor ......................................
7A3-27
Inspection .............................................................
7A3-27
Select Lever ....................................................... 7A3-28 Remove or Disconnect .......................................
7A3-28
Install or Connect .................................................
7A3-29
Shift Cable ......................................................... 7A3-31
Remove or Disconnect .......................................
7A3-31
Install or Connect .................................................
7A3-32
Torque specifications ..........................................
7A3-33
Transmission Control Module (TCM) ...................
7A3-34
Removal ................................................................
7A3-34
Installation .............................................................
7A3-34
Shift Solenoid and Lock-Up Solenoid ...................
7A3-35
Removal ................................................................
7A3-35
Installation .............................................................
7A3-36
Valve Body Assembly and Pressure Control Solenoid .................................................
7A3-37
Removal ................................................................
7A3-37
Installation .............................................................
7A3-39
Rear Oil Seal (Adapter Housing, 4

4) .................
7A3-40
Removal ................................................................
7A3-40
Installation .............................................................
7A3-40
Rear Oil Seal (Extension Housing, 4
2) ..............
7A3-41
Removal ................................................................
7A3-41
Installation .............................................................
7A3-41
Transmission Assembly .........................................
7A3-42
Transmission and Associated Parts .................
7A3-42
Removal ................................................................
7A3-43
Installation .............................................................
7A3-46
Major Components ..............................................
7A3-50

UNIT REPAIR (AW30–40LE) 7A4–1
TRANSMISSION
CONTENTS
UNIT REPAIR (AW30–40LE)
Major Components (1) ................................... 7A4–3
Major Components (1) and Associated
parts ........................................................... 7A4–3
Disassembly steps...................................... 7A4–3
Components (1) ............................................. 7A4–5
Reassembly ................................................ 7A4–5
Major Components (2) ................................... 7A4–7
Major Componets (2) and Associated
Parts ........................................................... 7A4–7
Disassembly ............................................... 7A4–8
Reassembly ................................................ 7A4–11
Major Components (3) ................................... 7A4–16
Major Components (3) and Associated
Parts ........................................................... 7A4–16
Disassembly ............................................... 7A4–17
Reassembly ................................................ 7A4–25
Diaassembly, Inspection and Reassembly
of minor Components ................................. 7A4–37
Oil Pump ........................................................ 7A4–38
Disassembly View ...................................... 7A4–38
Disassembly ............................................... 7A4–38
Inspection and Repair................................. 7A4–39
Reassembly ................................................ 7A4–41
OD Planetary Gear and OD Direct Clutch
Assembly (C–0).......................................... 7A4–43
Disassembled View .................................... 7A4–43
Disassembly ............................................... 7A4–44
Inspection and Repair................................. 7A4–47
Reassembly ................................................ 7A4–48
OD Support Assembly ................................... 7A4–53
Disassembled View .................................... 7A4–53
Disassembly ............................................... 7A4–53
Inspection and Repair................................. 7A4–54
Reassembly ................................................ 7A4–55
Direct Clutch Assembly (C-2) ........................ 7A4–58
Disassembled View .................................... 7A4–58
Disassembly ............................................... 7A4–59
Inspection and Repair................................. 7A4–60
Reassembly ................................................ 7A4–61
Forward Clutch Asseembly (C-1)................... 7A4–64
Disassembled View .................................... 7A4–64
Disassembly ............................................... 7A4–65
Inspection and Repair................................. 7A4–66
Reassembly ................................................ 7A4–67
Front Planetary Gear ..................................... 7A4–71
Disassembled View .................................... 7A4–71
Disassembly ............................................... 7A4–71
Inspection and Repair................................. 7A4–71
Reassembly ................................................ 7A4–72Planetary Sun Gear and No.1 One-Way
Clutch ......................................................... 7A4–73
Disassembled View .................................... 7A4–73
Disassembly ............................................... 7A4–74
Inspection and Repair ................................. 7A4–74
Reassembly ................................................ 7A4–75
Second Brake Assembly (B–2)...................... 7A4–77
Disassembled View .................................... 7A4–77
Disassembly ............................................... 7A4–77
Inspection and Repair ................................. 7A4–78
Reassembly ................................................ 7A4–78
Rear Planetary Gear Assembly and Output
Shaft ........................................................... 7A4–81
Disassembled View .................................... 7A4–81
Disassembly ............................................... 7A4–82
Reassembly ................................................ 7A4–84
First and Reverse Brake (B–3) ...................... 7A4–87
Disassembled View .................................... 7A4–87
Disassembly ............................................... 7A4–88
Reassembly ................................................ 7A4–89
Transmission Valve Body assembly .............. 7A4–92
Disassembled View .................................... 7A4–92
Disassembly ............................................... 7A4–93
Reassembly ................................................ 7A4–93
Lower Valve Body .......................................... 7A4–96
Cross Section ............................................. 7A4–96
Disassembly ............................................... 7A4–98
Inspection and Repair ................................. 7A4–103
Reassembly ................................................ 7A4–104
Upper Valve Body .......................................... 7A4–109
Cross Section ............................................. 7A4–109
Disassembly ............................................... 7A4–111
Inspection and Repair ................................. 7A4–115
Reassembly ................................................ 7A4–116
Transmission Case ........................................ 7A4–121
Disassembled View .................................... 7A4–121
Disassembly ............................................... 7A4–121
Reassembly ................................................ 7A4–122
Torque Converter........................................... 7A4–124
Inspection and Repair ................................. 7A4–124
Adapter Housing (4
4)................................. 7A4–125
Disassembled View .................................... 7A4–125
Disassembly ............................................... 7A4–125
Reassembly ................................................ 7A4–125
Ex tension Housing (4
2) ............................. 7A4–126
Disassembled View .................................... 7A4–126
Disassembly ............................................... 7A4–126
Reassembly ................................................ 7A4–126
Main Data and Specifications ........................ 7A4–128