change wheel ISUZU TF SERIES 2004 Owner's Manual

7D1-34 TRANSFER CONTROL SYSTEM

Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shft on the fly)
If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz and, at the
same time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes
out.
Cause of excessive synchronous shifting load

Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization)
 High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.

1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.

1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and axle, connecting the front wheel
and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed

, the indicator flashes
at a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.

2.
When shifting from 4H to 2H
2-1 When 4WD indicator continues flashing at 2Hz
When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed
. When torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle
is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.


: Shift on the fly only.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-53

 The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.

After more than 1 second has elapsed after the
ignition key has been turned “ON", short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids

Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.

When diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
 Check output speed sensor for proper mounting and
adjustment.


DTC P0722 (FLASHING CODE 11) Output Speed Sensor Signal Error


Step Action Value(s) YES NO
1
Was the powertrain On-Board Diagnostic (OBD)
System check performed ? — Go to Step 2 Go to OBD
system check
2

1. Install the scan tool.

2. Key “ON".
3. Review and record scan tool data

4. Operate the vehicle with in scan tool data.
Does the scan tool indicator DTC 0722 ? — Go to Step 3 Refer to
Diagnotic Aids
3 Measure the voltage of the output revolution sensor
by the J39200 DMM.

1. Key “OFF"
2. Lift the driving wheels.

3. Disconnect the output revolution sensor connector.

4. With engine idling in gear.
5. Measure the voltage between the output revolution
sensor connector terminal E81-1 and E81-2.
Does the scan tool indicate less than specified
value ? 3V Refer to
Diagnostic Aids Go to Step 4

7A3-32 ON-VEHICLE SERVICE (AW30 –40LE)

Install or Connect
1.
Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2.
Push the shift cable into the select lever base.
3.
Connect the shift cable to the select lever.
4.
Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5.
Check that the select lever is in the “N ” position.
6.
Check that the transmission is in the “N ” position.




249R300002
7.
Slide the cover in the direction shown by the arrow
(1).
8.
Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.

P1010012

9.
Connect the shift cable to the manual shaft select
lever at the transmission side.
10.
Insert the lock piece to the adjuster (cable length
adjustment).
11.
Slide the cover on the adjuster and secure lock
piece.

P1010016-2
11.
Press the select lever knob button 5 times.
Then check that the select lever moves smoothly to each of its positions.
13.
Check that the shift position indicated by the select
lever and the actual shift position are the same.
14.
Install the front console and rear console.
15.
Connect the negative battery cable.
16.
Remove the wheel blocks.

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

7A3-14 ON-VEHICLE SERVICE (JR405E)
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the “N” position.
6. Check that the transmission is in the “N” position.
249R300002
7. Slide the cover in the direction shown by the arrow
(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.
P1010012

9. Connect the shift cable to the manual shaft selec
t
lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.
P1010016-2
11. Press the select lever knob button 5 times.
Then check that the select lever moves smoothly to
each of its positions.
13. Check that the shift position indicated by the selec
t
lever and the actual shift position are the same.
14. Install the front console and rear console.
15. Connect the negative battery cable.
16. Remove the wheel blocks.

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.