brake ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 3687 of 4264
TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-7
TCM Voltage & Resistance Check Sheet
CHECK ITEM PIN No. VALUE NOTE
VIGN A6 –A1 VIGN
Key “ON ”
A6 –A23 VIGN
Key “ON ”
Backup Power Supply A24 –A1 +B (Always)
Key “ON ”
Inhibitor (Select) SW P B20 –A1 “P ” Range VIGN Key “ON ”
Except “P ” 0V
Inhibitor (Select) SW R B1
–A1 “R ” Range VIGN Key “ON ”
Except “R ” 0V
Inhibitor (Select) SW N B8
–A1 “N ” Range VIGN Key “ON ”
Except “N ” 0V
Inhibitor (Select) SW D B7
–A1 “D ” Range VIGN Key “ON ”
Except “D ” 0V
Inhibitor (Select) SW 2 B19
–A1 “2 ” Range VIGN Key “ON ”
Except “2 ” 0V
Inhibitor (Select)SW 1 B18
–A1 “1 ” Range VIGN Key “ON ”
Except “1 ” 0V
Inhibitor (Select) SW 3 B9
–A1 “3 ” Range VIGN Key “ON ”
Except “3 ” 0V
Power SW B13
–A1 ON 0V Key “ON ”
OFF VIGN
3rd Start SW B4
–A1 ON 0V Key “ON ”
OFF VIGN
Brake SW B22
–A1 ON VIGN Key “ON ”
OFF 0V
AT Oil Temperature
Sensor A11
–A12 20 C 4.6V Engine run.
155
C 1.1V
4L Signal B21
–A1 4L 0V Key “ON ”
2H/4H VIGN
Diag SW B12
–A1 ON VIGN Key “ON ”
OFF 0V
Shift Solenoid A (S1) A16
–A1 P VIGN Engine run.
R VIGN
N VIGN
D –1 VIGN
D –2 VIGN
D –3 0V
D –4 0V
Page 3692 of 4264
7A2-12 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)
Functions of Input / Output Components
Component Function
Transfer low signal Detects the transfer High/Low position.
OD Cancel signal Detects whether the cruise control unit is judged OD cancel mode.
Output revolution sensor
(Transmission) Detects the vehicle speed.
Input revolution sensor
(Transmission) Detects the input revolution (OD direct clutch drum revolution).
Engine revolution sensor Detects the engine revolution with CAN.
Throttle position signal Detects the throttle opening rate with CAN.
Neutral start switch Detects the select lever position.
Pattern select switch Detects whether the driver has selected "NORMAL" or "POWER" mode.
Brake lamp switch Detects whether the driver has pressed the brake pedal or not.
Oil temperature sensor Detects the oil temperature.
I
n
p
u t
Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.
I
n
p
u t
/
O
u t
p
u t Data link connector When connected with Tech2 or tester, can communicate the data for function
check, etc.
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle running condition on the
basis of TCM output.
Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running condition on the basis of TCM output.
Pressure control solenoid
STH Adjusts throttle pressure by energizing current of linear pressure control solenoid
to prevent the shift shock and to obtain shift smoothly.
"CHECK TRANS" lamp When trouble has occurred to throttle position sensor, vehicle speed sensor, or
solenoid, "CHECK TRANS" lamp is blinked to warn the driver. If also displays the
trouble code.
A/T OIL TEMP warning
lamp Lights when ATF oil temperature rises. (Turned on at greater than 146
C
(295
F). Turned off at less than 132
C (270
F).
POWER lamp Lights when POWER MODE detected.
O
u
t
p
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t
3rd Start lamp Lights when 3rd Start MODE detected.
C
o
m
p
u t
e r Transmission Control
Module (TCM) Based on the signal from each switch and sensors, judges necessary shift point
and lock-up operation, and send signal to each solenoid.
Page 3702 of 4264
7A2-22 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)
TRANSMISSION DATA
ITEM UNIT ENGIN RUNNING AT IDLE
Current Gear 1 st/2 nd/3 rd/4 th 1 st
Target Gear 1 st/2 nd/3 rd/4 th 1 st
Vehicle Speed km/h 0 km/h
AT Output Speed (Automatic Transmission) RPM 0 RPM
AT Input Speed (Automatic Transmission) RPM 675725 RPM
Engine Speed RPM 675725 RPM
Throttle Position Sensor Signal % 0.007.00%
AT Oil Temperature (Automatic Transmission) C Depends on conditions
TCM Status Transfer Low /Transfer High Transfer HI
Desired PC Solenoid Pressure (STH) kPa 34.397.0 kPa
Desired PC Solenoid Current (STH) mA 8351020 mA
PC Solenoid Actual Current (STH) mA 8351020 mA
Gear Ratio : 1 Depends on uper hood
TCC Slip Speed RPM 0 RPM
Shift Position Actual P/R/N/L/2/3 P
Inhibitor Switch P/R/N/L/2/3 P
Transmission Check Light On/Off Off
AT Oil Temperature Lamp (Automatic
Transmission) On/Off Off
3 rd Start Lamp On/Off Off
Power Lamp On/Off Off
Shift Solenoid S1 On/Off On
Shift Solenoid S2 On/Off On
Shift Solenoid S3 On/Off Off
Diag Switch Condition On/Off Off
Power Switch On/Off Off
Brake Switch On/Off Off
Cruise Switch On/Off Off
4L Signal On/Off Off
3 rd Start Switch On/Off Off
Coolant Temperature C Depends on conditions
Torque Request (timing Retard) CA 0 CA
Garage Shift Mode On/Off Off
CAN TPS % 0.00%
CAN Signal Valid Counter (ECM)
— 0 255
CAN Signal Valid Counter (TCM) — 0 255
Page 3757 of 4264
ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
TRANSMISSION
ON-VEHICLE SERVICE (AW30–40LE)
CONTENTS
Service Precaution .................................................
7A3-2
Location of Clutch, Brake, One-Way Clutch
and Solenoid ........................................................
7A3-3
Operation of Clutch, Brake and One-Way
Clutch ....................................................................
7A3-4
Trnasmission Indentification ..............................
7A3-4
Speed Change and Lock-Up Pattern ...............
7A3-5
Overdrive and Lock-Up Operating
Conditions ............................................................
7A3-5
Diagnosis .................................................................
7A3-6
Basic Troubleshooting ........................................
7A3-6
Manual Shifting Test ...........................................
7A3-12
Stall Test ..............................................................
7A3-12
Time Lag Test .....................................................
7A3-13
Hydraulic Test ......................................................
7A3-14
Road Test .............................................................
7A3-15
Shift Pont Chart and Lock-Up Point Chart ..........
7A3-19
Shift Pont Chart ...................................................
7A3-19
Lock-Up Point Chart ...........................................
7A3-20
Transmission Fluid Level and Condition .............
7A3-21
Inspection .............................................................
7A3-21
ATF Replacement ..................................................
7A3-22
Inspection .............................................................
7A3-22
Neutral Start Switch (Mode Switch) .....................
7A3-23
Inspection .............................................................
7A3-23
Removal ...............................................................
7A3-23
Installation ............................................................
7A3-23
Brake Signal ............................................................
7A3-24
Inspection .............................................................
7A3-24
Input and Output Revolution Sensor ....................
7A3-25
Inspection .............................................................
7A3-25
Pattern Select Switch .............................................
7A3-25
Inspection .............................................................
7A3-25
Solenoid ...................................................................
7A3-26
Inspection .............................................................
7A3-26
ATF Temperature Sensor ......................................
7A3-27
Inspection .............................................................
7A3-27
Select Lever ....................................................... 7A3-28 Remove or Disconnect .......................................
7A3-28
Install or Connect .................................................
7A3-29
Shift Cable ......................................................... 7A3-31
Remove or Disconnect .......................................
7A3-31
Install or Connect .................................................
7A3-32
Torque specifications ..........................................
7A3-33
Transmission Control Module (TCM) ...................
7A3-34
Removal ................................................................
7A3-34
Installation .............................................................
7A3-34
Shift Solenoid and Lock-Up Solenoid ...................
7A3-35
Removal ................................................................
7A3-35
Installation .............................................................
7A3-36
Valve Body Assembly and Pressure Control Solenoid .................................................
7A3-37
Removal ................................................................
7A3-37
Installation .............................................................
7A3-39
Rear Oil Seal (Adapter Housing, 4
4) .................
7A3-40
Removal ................................................................
7A3-40
Installation .............................................................
7A3-40
Rear Oil Seal (Extension Housing, 4 2) ..............
7A3-41
Removal ................................................................
7A3-41
Installation .............................................................
7A3-41
Transmission Assembly .........................................
7A3-42
Transmission and Associated Parts .................
7A3-42
Removal ................................................................
7A3-43
Installation .............................................................
7A3-46
Major Components ..............................................
7A3-50
Page 3759 of 4264
ON-VEHICLE SERVICE (AW30 –40LE) 7A3-3
Location of Clutch, Brake, One-Way Clutch and Solenoid
RUW37ALF000201
Legend
(8) One-way clutch (No.2) (F–2)
(1) Overdrive direct clutch (C–0) (9) Shift solenoid (S–1)
(2) Overdrive brake (B–0) (10) Shift solenoid (S–2)
(3) Direct clutch (C–2) (11) One-way clutch (No.1) (F–1)
(4) Second coast brake (B–1) (12) Pressure control solenoid (STH)
(5) Forward clutch (C–1) (13) Lock-up solenoid (SL)
(6) Second brake (B–2) (14) Overdrive one-way clutch (F–0)
Page 3760 of 4264
7A3-4 ON-VEHICLE SERVICE (AW30 –40LE)
Operation of Clutch, Brake and One-Way Clutch
Transmission Identification
RUW37ASH004301
Legend
(1)
Transmission Model Number
(2)
Production Serial Number
The identification plate is located on the right rear side
of the transmission.
Page 3761 of 4264
ON-VEHICLE SERVICE (AW30 –40LE) 7A3-5
Speed Change and Lock-Up Pattern
If you select a speed as shown below by specifying
respective positions of transmission shift lever, transfe
r
switch and pattern select switch, the transmission
control computer controls speed change and lock-up
operations based on the specified pattern in accordance
with the degree of throttle opening and vehicle speed.
Pattern select sw. position Transmission shift position
D 3 2 L
NORMAL, POWER 1st
[2nd]
[3rd]
[O/D] 1st
[2nd]
[3rd] 1st
2nd(3rd) 1st(2nd)
3rd START 3rd fixing — —
[ ]: The lock-up operation is available.
( ): Transmission is shifted at high speed to prevent overrun.
Overdrive and Lock-Up Operating Conditions
The overdrive and lock-up clutch operate if the following
conditions are satisfied.
Overdrive Lock-up clutch
Shift pattern position
NORMAL NORMAL
Transmission shift position
D range
Brake lamp switch
— OFF
Throttle opening
Fully closed Except fully closed
Accelerator About 52 km/h (32 mph) or more 2nd: About 76 km/h (47 mph) or
more
Vehicle speed Deceleration About 42 km/h (26 mph) or more 3rd: About 56 km/h (35 mph) or more
O/D: About 67 km/h (42 mph) or
more
Page 3769 of 4264
ON-VEHICLE SERVICE (AW30 –40LE) 7A3-13
Measure Stall Speed
1. Chock the four wheels.
2. Mount an engine tachometer.
3. Fully apply the parking brake.
4. Step down strongly on the brake pedal with your left foot.
5. Start the engine.
6. Turn off the A/C.
7. Shift into the “D" range. Step all the way down on
the accelerator pedal with your right foot. Quickl
y
read the highest engine rpm.
Stall speed: 2100
150 rpm
8. Perform the same test in the “R" range.
Evaluation
1. If the engine speed is the same for both ranges but
lower than the specified value:
Engine output is insufficient.
Stator one-way clutch is not operating properly.
NOTE: If more than 600 rpm below the specified value,
the torque converter could be faulty.
2. If the stall speed in “D" range is higher than
specified:
Line pressure too low
Forward clutch slipping
No.2 one-way clutch not operating properly
3. If the stall speed in “R" range is higher than
specified:
Line pressure too low
Direct clutch slipping
No.3 brake slipping
4. If the stall speed in the “R" and “D" ranges are
higher than specified:
Line pressure too low
Improper fluid level
Time Lag Test
F07RY00003
If the shift lever is shifted while the engine is idling,
there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the forward clutch, direct clutch, No.3
brake, and No.2 one-way clutch.
NOTE:
1. Perform the test at normal operation fluid
temperature (50 – 80 C or 122 – 176 F)
2. Be sure to allow one minute interval between tests.
3. Make three measurements and take the average value.
Page 3770 of 4264
7A3-14 ON-VEHICLE SERVICE (AW30 –40LE)
Measure Time Lag
1. Fully apply the parking brake.
2. Start the engine. Check idling speed (A/C OFF).
3. Shift the shift lever from “N" to “D" range. Using a
stopwatch, measure the time it takes from shifting
the lever until the shock is felt.
Time lag: Less than 0.7 seconds
4. In same manner, measure the time lag for “N"
“R".
Time lag: Less than 1.2 seconds
Evaluation
1. If “N"
“ D" time lag is longer than specified:
Line pressure too low
Forward clutch malfunction
No.2 one-way clutch not operating properly
2. If “N"
“ R" time lag is longer than specified:
Line pressure too low
Direct clutch malfunction
No.3 brake malfunction
3. If both time lag is longer than specified:
Line pressure too low
Hydraulic Test
RUW37ALH000201
Preparation
1. Warm up the transmission fluid.
2. Remove the transmission case test plug and mount the hydraulic pressure gauge.
Oil pressure gauge: J –29770 –A
NOTE: Perform the test at normal operation fluid
temperature (50 – 80
C or 122 – 176
F).
Page 3771 of 4264
ON-VEHICLE SERVICE (AW30 –40LE) 7A3-15
Measure Line Pressure
1. Fully apply the parking brake and chock the four
wheels.
2. Start the engine and check idling rpm.
3. Shift into “D" range, step down strongly on the brake
pedal with your left foot and, while manipulating the
accelerator pedal with the right foot, measure the
line pressures at the engine speeds specified in the
table.
4. In the same manner, perform the test in “R" range.
Line pressure kPa (kg/cm2/psi) Engine
speed “D" range “R" range
Idling 323 – 382
(3.3 – 3.9/47 – 55) 500 – 598
(5.1 – 6.1/73 – 87)
Stall 1,137 – 1,274 (11.6–13.0/165–185) 1,499 – 1,833
(15.3–18.7/218–266)
Evaluation
1. If the measured values at all ranges are higher than
specified:
Pressure control solenoid defective
Primary regulator valve defective
2. If the measured values at all ranges are lower than
specified:
Primary regulator valve defective
Oil pump defective
Pressure control solenoid defective
3. If pressure is low in “D" range only:
“ D" range circuit fluid leakage
4. If pressure is low in “R" range only:
“ R" range circuit fluid leakage
Road Test
NOTE: Perform the test at normal operation fluid
temperature (50 – 80
C or 122 – 176
F).
“D" Range Test in “NORMAL", and
“POWER" Pattern Ranges
Shift into the “D" range and hold the accelerator pedal
constant at the 50% and 100% throttle valve opening
positions.
Push in one of the pattern selector buttons and check
the following:
1. 1 –2, 2 –3, 3 –OD and lock-up, up-shifts should take
place, and shift points should conform to those
shown in the automatic shift diagram.
RUA370MH000101
RUA37ASH000101