oil change ISUZU TF SERIES 2004 Manual Online

7A2-116 DIAGNOSIS (JR405E)
When signal from the speed sensor becomes out of order, it may be judged a result of changed vehicle
speed and faulty gear shifting may be the causes.







Trouble in control valve body (faulty operation, sticking, clogged oil passage)



Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a position
other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select
cable.
2 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 3 Go to Step 3
3 Are any DTCs stored?
Go to DTC Chart Go to Step 4
4 Are the quantity, contamination and smell normal?

If the ATF level is
low, replenish up to
the specified level.

Go to Step 5
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.

DIAGNOSIS (JR405E) 7A2-121
No. E1: No Gear Shift

Description:

Range is fixed without shifting the gear of 1st to 2nd, 2nd to 3rd, and 3rd to 4th.

Gear may be shifted or may not be shifted.

Diagnosis Hints:

Fixing at some gear speed, signal error from throttle position sensor or trouble in the AT main unit are supposed.

Possible Cause:

Slip of clutch (low clutch, high clutch and 2-4 brake).
If slip of clutch is caused, a DTC (gear ratio error) is stored.

Dropped line pressure.

Fixing at 3rd position (fail-safe activated).
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "No gear shift"
is resulted. In this case, the DTC is memorized.
When TCM stops operation because of faulty TCM ground, the gear is fixed at the 3rd position because
of a mechanical reason. In this case, no DTC is memorized.





Incorrect properties of throttle opening signal (serial communication) of throttle position sensor.
Throttle opening signal (serial communication) of the throttle position sensor does not change in
proportion to the throttle opening. In this case, fixing at the high or low gear results in such a trouble
that "No Gear Shift".

Trouble in control valve body (faulty operation, sticking, clogged oil passage)

Step Action Yes No
1 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out).
Go to Step 2 Go to Step 2
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.

Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.

7A2-138 DIAGNOSIS (JR405E)
No. Z6: Poor Fuel Consumption

Description:

Poor fuel consumption.

Diagnosis Hints:

Basically same causes as "No. C1 - C8: Engine races up (slip) by shift up or shift down" are considered.



No. Z7: Pattern Select Switch is Faulty

Description:

Shift pattern does not change though the pattern select switch is turned on.

Possible Cause:

Faulty mode select switch is considered.



No. Z8: Oil is Splashed During the Running

Description:

Oil is splashed during the running

Possible Cause:

ATF quantity is too high.



No. Z9: Abnormal Smell

Description:

Abnormal smell.

Diagnosis Hints:

Basically a trouble in the AT main unit.



No. Z10: ATF Quantity is Low or High

Description:

Oil quantity is low or high.

Possible Cause:

In case of oil level is high.
ATF temperature is low when ATF quantity is checked.

In case of oil level is low.
ATF leaks is considered. Check the AT main unit and cooler circuit.

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20

ON-VEHICLE SERVICE (JR405E) 7A3-3
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20
C (68
F) before the
cold level check is made.
1. Park the vehicle on a level surface.
2. Apply the parking brake firmly.
3. Start the engine and allow it to warm up.
The engine coolant temperature gauge needle
should be midway between the “C” mark and “H”
mark.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each range just long enough for the
transmission to engage.
5. Return the select lever either “P” or “N”.
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.

9. Remove the dipstick.
The ATF level should be inside the “C”range on the
dipstick.
If the ATF level is below the “C” range, ATF must be
added.
242R300002


ATF CHANGE
1. Start the engine and allow it to idle until the ATF
reaches a temperature of 40-50
C
2. Park the vehicle on level ground and block the
wheels.
3. Stop the engine.
4. Raise vehicle and support with suitable safety
stands.
5. Remove the drain plug from the oil pan and drain the
ATF (approximately 6 liters).
6. Remove the oil pan.
7. Inspect the oil pan (details written below).
8. Install the oil pan.
Note:
Use new gasket. Clean the oil pan and magnet.
Oil pan bolt torque : 8 Nm (69 lbin)
9. Replace the gasket and install the drain plug.
Drain plug torque : 35 Nm (26 lbft)
Note:
Do not reuse old washer (gasket).
Clean the drain plug (especially the threaded section).
10. Pour about 5 liters of new ATF. Then, add more ATF
carefully as necessary using the dipstick.
Refer to “ATF LEVEL” previously in this section.
Note:
Keep the engine idle (do not stop it) during the oil level
adjustment.
11. Remove the safety stands and wheel blocks. Inspect
1. Check the drain plug tip for adhesion of foreign
substances.
2. Check the drained ATF for color, smell and inclusion
of foreign substances.
3. Check the oil pan bottom and magnet for adhesion o
f
foreign substances.
If a problem is discovered during those checks, the
Automatic transmission must be overhauled.
Note:
The torque converter and the oil strainer need replaced
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.
In addition, flush the ATF cooler circuit

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).

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.

Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil
Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
6. Fill the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. When the abnormal amount of debris are found.
2. When the abnormal wear or chips on gears and
shafts are found while overhauling.
3. When the abnormal clutch facing wear and oil
contamination are found.

Procedures
1. Block the wheels.
2. Disconnect negative battery cable.
3. Raise vehicle and support with suitable safety
stands.
4. Disconnect fluid cooler lines at transmission case
and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using
solvent and compressed air.
Note:
DO NOT exceed 197 kPa (29 psi) air pressure or
damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic
Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (33 lb·ft)
8. Replenish ATF
9. Start engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all
debris from the fluid cooler circuit.
Move the select lever through the various ranges and
return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF
must be added.
10. Connect negative battery cable.
11. Remove safety stands.
12. Remove wheel blocks.