oil OPEL FRONTERA 1998 Workshop Manual

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–41
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (Cont’d)
StepNo Ye s Action
8Replace TFT sensor. Refer to Transmission Oil Temperature
Sensor (Adapter Case) in Automatic Transmission (4L30–E)
section.
Is the replacement complete?
Go to Step 13—
9Check circuit RED/BLK–GRN/RED for an open or short to B+.
Was a problem found?
Go to Step 13Go to Step 10
10Check circuit GRY–GRN for an open.
Was a problem found?
Go to Step 13Go to Step 11
11Check the PCM for faulty or intermittent connections.
Was a problem found?
Go to Step 13Go to Step 12
12Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete?
Go to Step 13—
131. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
2. TFT sensor indicates a voltage less than 4.92 volts for 2
seconds.
3. Review the scan tool “DTC Info”.
Has the last test failed or is the current DTC displayed?
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–55
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
StepActionYe sNo
11. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. While the engine is operating, put the transmission in Park.
5. Using the scan tool, apply 0.1 amp through 1.0 amp while
observing “PC Ref. Current” and “PC Act. Current”.
Is the “PC Act. Current” reading always within 0.16 amp?
Go to Diagnostic
Aids
Go to Step 2
21. Turn the ignition “off”.
2. Disconnect the transmission 5–way connector M–6.
3. Using the J39200 DVOM, measure the resistance between
terminals M6–2(B) and M6–1(E).
Is the resistance within 3–7 ohms?
Go to Step 6Go to Step 3
31. Remove the transmission oil pan. Refer to Solenoid (Adapter
Case Valve Body) in Automatic Transmission (4L30–E)
section.
2. Disconnect the internal wiring harness at the PCS.
3. Measure the resistance of the PCS.
Is the resistance within 3–7 ohms?
Go to Step 5Go to Step 4
4Replace the PCS.
Is the replacement complete?
Go to Step 9—
5Repair the internal wiring harness for an open.
Is the repair complete?
Go to Step 9—
6Inspect/repair circuits J3–E4, M6–2(B), J3–E3, and M6–1(E).
Was a problem found?
Go to Step 9Go to Step 7
7Inspect/repair circuits J3–E4, M6–2(B), J3–E3, and M6–1(E) for
a short to ground or poor connections.
Was a problem found?
Go to Step 9Go to Step 8
8Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete?
Go to Step 9—
91. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
The PCS duty cycle is not at its electrical high or low limit.
2. Review the scan tool “DTC Info”.
Has the last test failed or is the current DTC displayed?
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–67
DTC P1850 Brake Band Apply Solenoid Malfunction
D07RW009
Circuit Description
The brake band apply solenoid is a normally open
solenoid which controls the flow of fluid for brake band
application. The Powertrain Control Module (PCM)
uses Pulse Width Modulation (PWM) and changes
the duty cycle to control the solenoid. The PCM turns
the solenoid on (energized) and off (deenergized) at a
constant frequency. The length of time the solenoid is
energized during each on/off cycle is called the pulse
width. By varying or “modulating” the pulse width, the
solenoid output pressure is changed. Since the
solenoid is normally open, increasing the pulse width
increases the duty cycle and decreases the output
pressure. PWM control provides smooth band
application without an accumulator. The band is only
applied in first and second gears.
In the event of an electrical failure (open), the
solenoid regulates at the maximum oil flow (0% duty
cycle).
The solenoid is activated by current. This current is
produced by applying a voltage to one side (the High
side) and a ground to the other side (Low side).
The High Side Driver (HSD) is a circuit of the PCM
that acts as a switch between the solenoids and the
supply voltage. The High side of the solenoid is
permanently supplied with voltage. When the ignition
is off, the HSD is turned off.This DTC detects a continuous open or short to ground in
the brake band apply solenoid circuit or the brake band
apply solenoid. This is a type “D” DTC.
Conditions For Setting The DTC
Battery voltage is between 10 and 16 volts.
Ignition is “on”, Engine “run”.
The PCM commands the solenoid “on” and the
voltage remains high (B+) or the PCM commands the
solenoid “off” and the voltage remains low (zero
volts).
All conditions met in 1.3 seconds.
Action Taken When The DTC Sets
Inhibit brake band apply solenoid.
The PCM will not illuminate the CHECK TRANS
Lamp.
Conditions For Clearing The DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–71
DTC P1860 TCC Solenoid Electrical
D07RW010
Circuit Description
The PCM allows current to flow through the solenoid coil
according to the duty cycle (percentage of “on” and “off”
time). This current flow through the solenoid coil creates
a magnetic field that magnetizes the solid core. The
magnetized core attracts the check ball to seat against
spring pressure. This blocks the exhaust for the TCC
signal fluid and allows 2–3 drive fluid to feed to TCC signal
circuit. The TCC signal fluid pressure acts on the TCC
regulator valve to regulate line pressure and to apply fluid
pressure to the torque converter clutch shift valve. When
the TCC shift valve is in the apply position, regulated
apply fluid pressure is directed through the TCC valve to
apply the torque converter clutch. The TCC solenoid is
used in conjunction with the TCC solenoid to regulate fluid
to the torque converter. The TCC solenoid is attached to
the valve body within the transmission.
This DTC detects a continuous open or short to ground or
ignition in the TCC circuit or the TCC solenoid. This is a
type “D” DTC.
Conditions For Setting The DTC
Battery voltage is between 10 and 16 volts.
No shift solenoid A DTC P0753.
No shift solenoid B DTC P0758.
Ignition is “on”, Engine “run”.
The PCM commands the solenoid “on” and the
voltage remains low (zero volts).
The PCM commands the solenoid “off” and the
voltage remains high (B+).
All conditions met for 0.25 seconds.
Action Taken When The DTC Sets
Inhibit TCC engagement.
The PCM will not illuminate the CHECK TRANS
Lamp.
Conditions For Clearing The MIL/DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Diagnostic Aids
Inspect the wiring for poor electrical connections at
the PCM and at the transmission 16–way connector.
Look for possible bent, backed out, deformed or
damaged terminals. Check for weak terminal tension
as we ll. A lso ch eck fo r a ch af e d w ire th at cou l d s ho r t
to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
Test Description
The numbers below refer to the step numbers on the
diagnostic chart:
3. This test checks for voltage to the solenoid.
4. This test checks the ability of the PCM and wiring to
control the ignition circuit.
9. This test checks the resistance of the TCC solenoid
and the internal wiring harness.

MANUAL TRANSMISSION7B–1
TRANSMISSION
MANUAL TRANSMISSION
CONTENTS
Service Precaution 7B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 7B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 7B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Assembly 7B–5. . . . . . . . . . .
Transmission and Associated Parts 7B–5. . . . . .
Removal 7B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Transfer Adapter) 7B–17. . . . . . . . . .
Removal 7B–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7B–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission (AR-5) 7B–18. . . . . . . . . . . . . . . . . . . . .
Disassembled View 7B–18. . . . . . . . . . . . . . . . . . . .
Disassembly 7B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 7B–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7B–41. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 7B–68. . . . . . . . . . . . .
General Specifications 7B–68. . . . . . . . . . . . . . . . .
Torque Specifications 7B–69. . . . . . . . . . . . . . . . . .
Special Tools 7B–72. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH 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.

7B–4MANUAL TRANSMISSION
Diagnosis
ConditionPossible causeCorrection
Abnormal noiseFlywheel pilot bearing wornReplace
Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)Replace
Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)Replace
Splines worn (Mainshaft,
synchronizer clutch hub)Replace
Gear or bearing thrust face seizedReplace
Lack of backlash between meshing
gearsReplace
Hard ShiftingImproper clutch pedal free playReadjust
Change lever sliding portions wornRepair or replace
Regrease
Shift block, shift rod and/or control
box sliding faces wornReplace
Shift arm and synchronizer sleeve
groove wornReplace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)Replace worn parts
Synchronizer parts wornReplace
Walking or Jumping out of gearDetent ball wornReplace
Detent spring weakened or brokenReplace
Shift rod and/or control box sliding
faces wornReplace
Shift arm and synchronizer sleeve
groove wornReplace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)Replace worn parts
Bearings worn or brokenReplace
Splines worn (Mainshaft,
synchronizer hub)Replace
Synchronizer spring weakened or
brokenReplace
Oil leakageLoose drain plug(s) and/or filler
plug(s)Tighten
Replenish oil
Defective or improperly installed
gasket(s)Replace
Oil seal worn or scratchedReplace

MANUAL TRANSMISSION7B–17
Rear Oil Seal (Transfer Adapter)
Removal
1. Remove the transfer case assembly from the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
2. Remove the rear oil seal from the transfer adapter.
220RW090
Installation
1. Use 5–8840–2558–0 (J–42802) transfer adapter oil
seal installer, and install the rear oil seal to the transfer
adapter.
2. Apply grease to the oil seal lip.
3. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
220RW115

7B–20MANUAL TRANSMISSION
220RW095
Legend
(1) Release Bearing and Shift Fork
(2) Clutch Housing
(3) Front Cover
(4) Snap Ring
(5) Snap Ring
(6) 1st and 2nd Switch
(7) Drain Plug
(8) Backup Light Switch
(9) Transmission Case(10) Filler Plug
(11) Gear Control Rod
(12) Reverse Restrict Pin
(13) Oil Receiver Pipe
(14) Transfer Adapter
(15) Plug (6VE1) or Neutral Switch (4JX1)
(16) Gear Control Box
(17) Shift Lever Housing
(18) Oil Seal
(19) Plug

MANUAL TRANSMISSION7B–23
3. Using the M8 1.25 bolt, remove the gear control
rod and the shift lever hausing.
NOTE: Turn the M8 bolt a few times, before remove the
gear control rod.
220RW098
4. Remove the 10 bolts and clamp.
220RW016
5. Using a plastic hammer, tap the transfer adapter.
NOTE:
Be careful not to lose the pin.
Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
220RW015
7. Disassemble the transfer adapter assembly.
1. Using a torx socket wrench(T40), remove the
plug.
220RW013

7B–24MANUAL TRANSMISSION
2. Using a pin punch and hammer, drive out the
slotted spring pin. Remove the reverse restrict
pin.
220RW012
3. Remove the oil receiver pipe.
220RW011
4. Remove the oil seal.
5. Using socket hexagon wrench, remove the plug.
220RW014
8. Remove the front cover.
1. Remove the 8 bolts.
220RW018