TCM ISUZU TF SERIES 2004 Workshop Manual

DIAGNOSIS (JR405E) 7A2-129
Step Action Yes No
6 Inspect the output voltage and throttle opening signal of the
throttle position sensor using a Tech 2 or circuit tester.
Is a voltage value in proportion to the throttle opening output?




TPSTCM
A16
C56
(28)C94
(16) RED/ WHT
C56
(49)
(38)
(57)
(69)ECM
A47 (GND)
A35 (Out put )
A26
A55 (+5V)
A69 (I dl e SW)
Go to Step 7
Repair the defect or
replace.
7 Check of power supply to and earth of TCM.
Are the power supply and earth proper?




TCM
A1 (+B)
B5
B15
H23
(15)C95
(5)
(15) BLK/YEL
BLK BLK Battery
C94
(1)
BLK
Go to Step 8
Check the power
source harness and
earth harness (bolt
tightening to the
body).
8 Is the stall revolution correct in D, 3, 2 and L range? Refer the
STALL TEST section in this manual.
Go to Step 6
Repair the defect or
replace.
9 Is the line pressure correct? Refer the LINE PRESSURE TEST
section in this manual. Trouble in the AT
assembly or control
valve.
Repair the defect or
replace.

DIAGNOSIS (JR405E) 7A2-135
Step Action Yes No
3 Inspection of electrical or mechanical fault
When the ATF oil temperature is above 20C and the vehicle
speed is 80km/h, is ON signal issued to the lock-up solenoid
using the Tech 2 or circuit tester?
Control Valve

TCM
B17
B23 BLK Lock-up Solenoid

Terminal
Assembly
VIO Line Pressure Solenoid

E54
(4)
(6)H23
(14)
(6)C95
(17)
(23) BLK
VIO
TCM terminal
Lock-upB17
At lock-up Approx. 2.2 - 9.0V (AC range)
At unlock-up Approx. 1.0 – 2.0V (AC range)
Clogged oil
passage of lock-up
solenoid or faulty
operation of lock-
up piston. Go to Step 4
4 Inspection of ATF oil thermo sensor.
Is the ATF oil temperature sensor terminal voltage correct?
After running using the Tech 2 data display function, is the ATF
temperature higher than 10C?

AT F
Te m p .
SensorTCM
B4 (+)
B14 (-)
H23
(8)
(3)C95
(4)
(1 4) BLU Te r m in a l
Assembly
BLU/BLKE54
(2)
(8) BLU
BLU/BLK
TCM terminal
Temperature (deg. C)
B4 (Output voltage)
201.55
401.08
600.7
800.5
1000.3
1200.2
Monitor the electric
system input
sensor signal and
find a signal
causing no lockup.
Repair the defect or
replace.

7A2-154 DIAGNOSIS (JR405E)
TCM VOLTAGE CHECK




TCM voltage check is done to check for transmission and TCM
problems which cannot be detected by self-diagnosis.
Additionally, it severs as a back-up check for self-diagnosis.
Measure the voltage drop and make a continuity test for each of
sensors, solenoids and switches.
If the voltage is within the specified range and continuity exists,
that particular area of the TCM and transmission assembly is
normal.
If voltage deviation or lack of continuity is discovered, disconnect
the applicable parts and check of them individually.

Inspection Tool
Use a circuit tester and an oscilloscope to measure voltage and
circuit continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.

TCM Pin Assignment












       
 






 




       
  


















 


Connect to White Connector Connect to Grey Connector


No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
A1 RED V BATT (Battery Back-up Power
Supply) Input Battery Voltage - 10 – 14.5V Related
harness
At P range 10 – 14.5V Related
harness
A2 YEL/
VIO P Range Switch Input Inhibitor switch Voltage
At other than
P range Less than 2VInhibitor
switch
At brake
stepped 10 – 14.5V Related
harness
A3 RED Brake Switch Input Brake switch Voltage At brake no
stepped Less than 2V Brake switch
At lamp OFF 10 – 14.5V Related
harness A4 PNK/
WHT 3rd Start Indicator Lamp Output 3rd start lamp Voltage
At lamp ON Less than 2V Lamp
A5 GRN K-line signal (Tech 2 serial
communication) Input/
OutputTech 2 - - - Related
harness
A6 - - - - - - - -

DIAGNOSIS (JR405E) 7A2-155
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
Related
harness
Engine
Speed
Sensor A7 BLK/
RED Engine Speed Sensor Input ECM Voltage (Wave
form) At 2000rpm.
Circuit tester
(+) to A7 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.2V)
ECM
A8 - - - - - - - -
A9 - - - - - - - -
Related
harness
Speed
sensor
Speed meter
A10 BLK/
YEL Vehicle Speed Sensor Out (2WD Only) Output Speed meter Voltage (Wave
form) At run in L
range in 1st
gear 20 km/h.
Circuit tester
(+) to A10 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.5V)
TCM
At switch
pushed Less than 2VRelated
harness
A11 GRN/
WHT 3rd Start Select Switch Input 3rd start switch Voltage
At switch off 10 – 14.5V 3rd start
switch
At 4L Less than 2VRelated
harness
A12 BLU/
WHT 4L Mode Switch (4WD Only) InputTransfer control
unit Voltage
At other than
4L 10 – 14.5V 4L switch
A13 - - - - - - - -
A14 - - - - - - - -
A15 - - - - - - - -
At fully close Off duty 10%Related
harness
ECM A16 RED/
WHT Throttle Position Sensor Input ECM Wave form
(140Hz Duty
signal) *1
At fully open Off duty 90%Throttle
position
sensor
At 3 range 10 – 14.5V Related
harness
A17 BLK/
GRN 3 Range Switch Input Inhibitor switch Voltage
At other than
3 range Less than 2VInhibitor
switch
At key switch
ON 10 – 14.5V Related
harness
A18 YEL/
BLK DIAG Switch InputData link
connector Voltage
At short circuit
of DIAG
switch Less than 2VRelated
harness
At lamp OFF 10 – 14.5V Related
harness A19 ORG/
BLU A/T OIL TEMP Indicator Lamp OutputAT OIL TEMP
indicator lamp Voltage
At lamp ON Less than 2V Lamp
At lamp OFF 10 – 14.5V Related
harness A20 GRN/
YEL CHECK TRANS Indicator Lamp OutputCHECK TRANS
indicator Lamp Voltage
At lamp ON Less than 2V Lamp
At lamp OFF 10 – 14.5V Related
harness A21 PNK POWER DRIVE Indicator Lamp OutputPOWER DRIVE
indicator lamp Voltage
At lamp ON Less than 2V Lamp
A22 - - - - - - - -
A23 - - - - - - - -

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

7A3-4 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION CONTROL MODULE (TCM)



RTW37ALF001901

Remove and Disconnect
1. Disconnect the negative battery cable.
2. Remove the connectors.
3. Remove the fixing nuts and remove the TCM (1)
from the bracket.
Note:
The TCM is fitted under instrument panel of the driver’s
compartment by means of three stud bolts.


Install or Connect
Follow the removal steps in the reverse order. Be
absolutely sure that the connectors are securely
fastened.
AT CONT

7A3-8 ON-VEHICLE SERVICE (JR405E)
SPEED SENSOR
The speed sensor is attached to the right side of the
transmission.
240L300001
Legend
1. Inhibitor switch
2. Speed sensor
3. Turbine sensor


Inspect
1. During the driving at speed of 20km/h (12mph) with
“L” range in low gear, measure the voltage between
the TCM connector terminals (B13) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)






RTW47ASH000801
2. If the voltage is out of the standard value, check the
speed sensor pole piece for presence of foreign
meterials and the speeed sensor cable for short o
r
open circuit.
Result of the inspection is normal, replace the speed
sensor.
Torque: 6 N·m (52 lb·in)

ON-VEHICLE SERVICE (JR405E) 7A3-9
TURBINE SENSOR
The turbine sensor is attached to the right side of the
transmission.

Inspect
1. During the driving at speed of 20km/h (12mph) with
“L” range in low gear, measure the voltage between
the TCM connector terminals (B3) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)
2. If the voltage is out of the standard value, check the
turbine sensor pole piece for presence of foreign
materials and the turbine sensor cable for short o
r
open circuit.
Result of the inspection is normal, replace the
turbine sensor.
Torque: 6 N·m (52 lb·in)



POWER AND 3RD START SWITCH
Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Pry out the switch from the floor console.
4. Disconnect the harness connector.
5. Check continuity between terminal (5) and (6) at third
(3rd) position.
6. Check continuity between terminals (3) and (6) a
t
power (PWR) position.
7. Replace the power and 3rd start switch when the
result of inspection is found abnormal.
8. Connect the harness connector.
9. Connect the negative battery cable.
10. Remove the wheel blocks.
238R300003