torque ISUZU AXIOM 2002 Service Repair Manual

6G±13
ENGINE LUBRICATION (6VE1 3.5L)
Main Data and Specification
General Specification
ItemSpecificationsItem6VE1
Oil capacity5.3 liters
Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil
strainer
E06R100004

6H±1 ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
ENGINE SPEED CONTROL SYSTEM
CONTENTS
Service Precaution 6H±1. . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal 6H±2. . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal and Associated Parts 6H±2. . Removal 6H±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6H±2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

INDUCTION (6VE1 3.5L)6J±1
AXIOM
ENGINE
INDUCTION (6VE1 3.5L)
CONTENTS
Service Precaution 6J±1. . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Element 6J±2. . . . . . . . . . . . . . . . . . . . .
Removal 6J±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 6J±2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6J±2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

7A±2
AUTOMATIC TRANSMISSION (4L30±E)
Main Case Valve Body 7A±71. . . . . . . . . . . . . . . . . . .
Disassembled View 7A±71. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±71. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±72. . . . . . . . . . . . . . . . . .
Reassembly 7A±72. . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body 7A±73. . . . . . . . . . . . . . . .
Disassembled View 7A±73. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±73. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±73. . . . . . . . . . . . . . . . . .
Reassembly 7A±74. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch And Sprag Unit 7A±75. . . . . . . . . . . . . .
Disassembled View 7A±75. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±75. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±75. . . . . . . . . . . . . . . . . .
Reassembly 7A±76. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch 7A±77. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A±77. . . . . . . . . . . . . . . . . . . .
Disassemble 7A±77. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±77. . . . . . . . . . . . . . . . . .
Reassembly 7A±77. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprag Unit 7A±79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A±79. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±79. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±79. . . . . . . . . . . . . . . . . .
Reassembly 7A±79. . . . . . . . . . . . . . . . . . . . . . . . . . Second Clutch 7A±80. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A±80. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±80. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±81. . . . . . . . . . . . . . . . . .
Reassembly 7A±81. . . . . . . . . . . . . . . . . . . . . . . . . .
3±4 Accumulator Piston 7A±82. . . . . . . . . . . . . . . . . .
Disassembled View 7A±82. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±82. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±83. . . . . . . . . . . . . . . . . .
Reassembly 7A±83. . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Clutch Piston And Center Support 7A±84.
Disassembled View 7A±84. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±84. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±85. . . . . . . . . . . . . . . . . .
Reassembly 7A±85. . . . . . . . . . . . . . . . . . . . . . . . . .
Overrun Clutch And Turbine Shaft 7A±86. . . . . . . . .
Disassembled View 7A±86. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±87. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±87. . . . . . . . . . . . . . . . . .
Reassembly 7A±87. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specification 7A±89. . . . . . . . . . . . . .
General Specifications 7A±89. . . . . . . . . . . . . . . . .
Torque Specifications 7A±90. . . . . . . . . . . . . . . . . .
Special Tools 7A±93. . . . . . . . . . . . . . . . . . . . . . . . . . .
4L30±E Parts List 7A±96. . . . . . . . . . . . . . . . . . . . . . .
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.

7A±3 AUTOMATIC TRANSMISSION (4L30±E)
Construction
A07R100002
Legend
(1) Torque Converter Clutch (TCC)
(2) Overdrive Free Wheel (One Way Clutch)
(OFW)
(3) Fourth Clutch (C4)
(4) Overrun Clutch (OC)
(5) Overdrive Unit(6) Reverse Clutch (RC)
(7) Second Clutch (C2)
(8) Third Clutch (C3)
(9) Principle Sprag Assembly (One Way Clutch)
(PFW)
(10) Ravigneaux Planetary Gear Set
(11) Brake Band (B)

7A±5 AUTOMATIC TRANSMISSION (4L30±E)
Normal Operation Of 2002 4L30±E
Transmission
Torque Converter Clutch (Electronically
Controlled Capacity Clutch : ECCC)
Application Conditions:
The clutch apply is controlled by moving the converter
clutch control valve by commanding Torque Converter
Clutch (TCC) solenoid using the PWM signal.
The TCC is normally applied in 2nd, 3rd and 4th gears
only when all of the following conditions exist:
Ð The engine coolant temperature is above 70
C
(158
F) and ATF temperature is above 18
C
(64.5
F).
Ð The shift pattern requests TCC apply.
Moreover, TCC is always applied in 2nd, 3rd and 4th
gears when the transmission oil temperature is above
135
C (275
F).
This mode should be canceled at 125
C (257
F).
ATF Warning Lamp
The ATF warning lamp will be constantly on (not flashing)
if the transmission oil temperature is above 145
C
(293
F).
The ATF warning lamp goes off again when the
transmission oil temperature is below 125
C (257
F).
Reverse Lock Out
With the selector lever in reverse position, the PCM will
not close the PWM solenoid until the vehicle is below 11
km/h (6.8 mph), thus preventing reverse engagement
above this speed.
Diagnosis
Introduction
The systematic troubleshooting information covered by
this Section offers a practical and systematic approach to
diagnosing 4L30±E transmission, using information that
can be obtained from road tests, electrical diagnosis, oil
pressure checks or noise evaluation.
The key to correcting a complaint is to make use of all of
the available symptoms and logically letting them direct
you to the cause.
When dealing with automatic transmission complaints, it
is best to gather as many symptoms as possible before
making the decision to remove the transmission from the
vehicle.
Frequently, the correction of the complaint does not
require removal of the transmission from the vehicle.
Driver Information
To analyze the problem fill out a complete description of
the owner's complaint.
Please draw a circle around the right information and
complete the following form. (The next page is an
example of a completed form). You can draw a circle
around many numbers if you are not sure.

7A±10
AUTOMATIC TRANSMISSION (4L30±E)
Checking Transmission Fluid Level
and Condition
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT:When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON )±III.
Refer to
Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnor-
mal shifting and possible damage to the transmis-
sion.
1. Park the vehicle on level ground and apply the parking
brake firmly.
2. Check fluid level with engine running at idle.
NOTE: Be sure that transmission fluid temperature is
below 30
C (86
F).
3. Move the selector lever through all gear ranges.
4. Move the selector lever to ªParkº.
5. Let engine idle for 3 minutes and open the overfill
screw (1).
6. Add released transmission fluid until it flows out over
the overfill screw opening.
7. Let engine idle until a fluid temperature between 32
C
(90
F) and 57
C (135
F) is reached, then close the
overfill screw (1).
Torque: 38 Nwm (28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.NOTE: Check transmission fluid temperature with scan
tool.
Minimum fluid level " 57
C (135
F)
Maximum fluid level " 32
C (90
F)
242R200001
CAUTION: Do not open overfill screw with engine
stopped.
CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:

Immediately after driving at sustained highway
speeds.

In heavy city traffic during hot weather.

If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to ªcoolº for thirty
(30) minutes. After the cool down period, restart the
vehicle and continue from step 2 above.

7A±13 AUTOMATIC TRANSMISSION (4L30±E)
Mechanical / Hydraulic Diagnosis Symptoms Index
Perform Preliminary Inspection First!
CHART
SYMPTOMS
1NO ENGINE START IN NEUTRAL OR PARK
2NO FORWARD GEARS IN ANY RANGE/NO REVERSE
3NO ENGINE BRAKE IN ANY RANGE
4POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)
5aDELAYS IN DRIVE AND REVERSE
5bDELAYS IN REVERSE ONLY
6DIAGNOSTIC TROUBLE CODE (DTC) P0730
7HARSH 1±2 SHIFT
8HARSH 3±4 SHIFT
9a3±2 DOWNSHIFT COMPLAINT
9bHARSH SHIFT WHEN SHIFTING INTO ªDº OR ACCELERATING FROM STOP
9cCOASTDOWN HARSH SHIFT OR CLUNK AT 3±2 DOWNSHIFT
10INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED
11ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)
12ENGINE FLARE DURING 1±2 OR 2±3 SHIFT
13SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING
14POSSIBLE CAUSES OF TRANSMISSION NOISE
15aPOSSIBLE CAUSES OF LOW LINE PRESSURE
15bPOSSIBLE CAUSES OF HIGH LINE PRESSURE
16POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
NOTE: Numbers with parenthesis on the following charts
refer to
Parts List at end of this section.
Chart 1: No Engine Start In Neutral Or Park
StepActionYe sNo
1Does engine start when shift lever moved from drive to neutral
mostly in hot condition?
Go to Step 2Go to Step 3
2Does engine start in park at any condition?Re±test vehicleGo to Step 4
3Does engine also not start in neutral when shift lever moved from
park to neutral?
Go to Step 4Go to Step 5
4Check mode switch (63) setting. Readjust if necessary.
Problems fixed?
Re±test vehicleGo to Step 5
5Check start circuit of mode switch (63) open in neutral.
Was open found?Locate and repair
open(s)Replace mode
switch (63)

7A±19 AUTOMATIC TRANSMISSION (4L30±E)
Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
StepActionYe sNo
11. TCC shudder is one of the most commonly misdiagnosed
conditions in an automatic transmission. The key to
diagnosing TCC shudder is to note when it happens and under
what conditions. Once the TCC has been fully applied, it is
nearly impossible to make it shudder. TCC shudder (short
burst of noise normally less than 1 second) will only occur
during clutch applying. It is not a steady state condition.
2. Drive until whole drivetrain is at normal operating temperature.
± On 4WD vehicles, the test must be performed with transfer
case selector lever in ª2Hº position.
± Shudder is a short burst of noise normally less than 1 second
in duration, and can be induced by the following maneuver:
3. From coast condition at 50 mph in ªDº range (Normal mode),
depress the throttle to 1/4-1/3 throttle. If present, shudder will
occur within 5 seconds together with TCC application.(The
scan tool may be used to determine the exact time of TCC
applying)
Was the problem found?
Replace
transmission fluid
and filter (remove
both pans) and
flush cooler lines.
Replace
converter
assembly and
O-ring on turbine
shaft
Perform
mechanical
inspection of
other drivetrain
components.
Chart 14: Possible Causes Of Transmission Noise
CAUTION: Before checking transmission for what
is believed to be transmission noise, ensure
presence and positioning of insulating plugs, pads
etc. Also make sure that noise does not come from
other drivetrain components.
Condition
Possible causeCorrection
Whine or BuzzOil level lowFill with ATF, check for external
leaks.
Plugged or restricted oil filterInspect oil filter.
Replace oil filter or ATF as necessary.
Damaged oil filter gasketReplace oil filter gasket.
Knocking noise from front of
transmission
Loose bolts (Converter to flex plate)Tighten to specifications.
transmission.Cracked or broken flex plateReplace flex plate.
Converter damagedReplace converter.
Knocking noise while driving, mostly
on acceleration.Transmission mount loose or brokenTighten mount bolts or replace
transmission mount.
Cooler line mounts loose or brokenTighten or replace cooler line
mounts.
Cooler lines touching body or frameRepair or replace as necessary.
Knocking noise when vehicle is
stationary
Loose flex plate mounting boltsTighten to specifications.
stationary.Cracked or broken flex plateReplace flex plate.
Damaged converterReplace converter.

7A±22
AUTOMATIC TRANSMISSION (4L30±E)
Chart 16: Possible Causes Of
Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
ªwind flowº around the engine and transmission.
The suspected area should be wiped clean before in-
specting for the source of the leak.Oil leaks around the engine and transmission are gener-
ally carried toward the rear of the vehicle by the air
stream. In determining the source of an oil leak, the fol-
lowing two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor O±Ring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal(9) Oil Cooler Connectors (2)
(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)