battery ISUZU TF SERIES 2004 Workshop Manual

7A2-36 TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)

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.
DTC P0560 – System Voltage 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 Using a DVM, measure the battery voltage at the
battery.
Is the battery voltage greater than the specified
value? 11.5 V Go to Step 3 Charge battery,
then go to Step
3
3

1. Install a Tech 2.

2. Select “Ignition Volts" on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.

4. Load the electrical system by turning on the
headlights, high blower, etc.
Is the ignition voltage approximately equal to the
specified value? 2000 RPM
12.8-14.1 VGo to Step 4 Go to
Starting/Chargi
ng
4

1. Ignition “OFF".

2. Disconnect the TCM connector at the TCM.

3. Using a DVM, measure the battery voltage at the
TCM connector C-94.
Is it approximately equal to battery voltage? — Check for
excessive
curren draw
with ignition
“OFF" engine
“OFF". Go to Step 5
5

1. Check for faulty connections at the TCM harness
terminals.

2. Repair as necessary.
Was a repair necessary? — Verify repair Go to Step 6
6 Check for an open battery feed circuit to the TCM.
Is the action complete? — Verify repair Go to Step 7
7 Replace the TCM.
Important:
The replacement TCM must be
programmed. (Refer to SPS for procedure.)
Is the action complete? — Verify repair —

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-23

Neutral Start Switch (Mode Switch)
Inspection
With a circuit tester, make a continuity test on the
neutral start switch with the moving piece set in each
position.










RTW37BSH000101
Removal
Preparation:
Disconnect negative ( –) battery cable.
1. Remove the rear side ATF cooler pipe from the
transmission elbow.
2. Disconnect neutral start switch connector.
3. Unstake the lock washer, and then remove the shaft
nut.
4. Remove the neutral start switch.
Installation
To install, follow the removal steps in the reverse order,
noting the following points;
If a engine starts at any selector position except “N ” o
r
“ P ”, the neutral start switch (mode switch) should be
adjusted.
1. Loosen the neutral start switch bolt and set the shift
selector to the “N" range.
2. Align the groove and neutral basic line.
3. Hold in position and tighten the bolt and nut.
Torque:
Nut – 7 N 


m (61 Ib in)
Bolt – 13 N 


m (113 Ib in)
4. Lock the nut with the lock washer tubs at two points.



RUW17ASH013601

7A3-26 ON-VEHICLE SERVICE (AW30 –40LE)

Solenoid
Inspection

1. Resistance check

Using an ohmmeter, check the resistance
between each terminals (S1/S2/SL) and body.
Solenoid S1, S2 and lock-up solenoid SL
resistance:
11 – 15






(at 20
 
C)
(Reference) 12 – 16






(at 40
 
C)

Using an ohmmeter, check the resistance
between each terminals (STH) and (STHG).
Pressure control solenoid resistance:
5 – 5.6






(at 20
 
C)
(Reference) 5.4 – 6.1






(at 40
 
C)



220L100001
NOTE: If the pressure control solenoid resistance is not
within speciation, replace the valve body assembly.



2. Operation check
Check the solenoid operation by blowing into an oil
hole as shown in the figure.
Solenoid S1 and S2 (Normal close type)


When battery terminal is disconnected No air leaks
When battery terminal is
connected Air passes through

Lock-up solenoid SL (Normal open type)



When battery terminal is disconnected Air passes through
When battery terminal is
connected No air leaks





244RX00001




244RY00005

7A3-28 ON-VEHICLE SERVICE (AW30 –40LE)

Select Lever



RTW37ALF001101
Legend

(6) Base plate
(1) Rear console
(7) Grooved pin
(2) Front console
(8) Spring plate
(3) Select lever knob
(9) Lever assembly
(4) Upper housing
(10) Sleeve
(5) Lamp assembly


Remove or Disconnect
1.
Block the wheels.
2.
Disconnect the negative battery cable.
3.
Remove the rear console and the front console.
4.
Remove the 2 screws fixing the select lever knob.

5.
Remove the knob together with the knob button and
spring from the lever.
6.
Turn the sleeve counterclockwise to remove it. Make
a note of the number of turns required to free the
sleeve.
7.
Remove the harness connectors from the base plate.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-31

Shift Cable





RTW47ALF000101
Legend

(5) Bracket
(1) Select lever
(6) Clip
(2) Shift cable retaining pawl
(7) Shift cable
(3) Manual shaft select lever
(8) Select lever base
(4) Adjuster


Remove or Disconnect
1.
Block the wheels.
2.
Disconnect the negative battery cable.
3.
Move the select lever to the “N ” position.
4.
Remove the rear console and front console.
5.
Disconnect the shift cable from the select lever.
6.
Press on the shift cable retaining pawl to remove the
cable from the select lever base.
7.
Disconnect the shift cable from the transmission
side.
8.
Remove the shift cable from the bracket.
9.
Pull the shift cable free from the bottom of the
vehicle.

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.

7A3-34 ON-VEHICLE SERVICE (AW30 –40LE)

Transmission Control Module (TCM)


RTW37ALF001801
Removal
Preparation:
Disconnect negative ( –) battery cable.
1. Disconnect the TCM harness connectors.
2. Remove fixing nuts (2 pieces) and TCM with bracket from the car.
NOTE: The TCM is fitted under instrument panel of the
driver's compartment by means of two stud bolts.
3. Remove fixing nuts (2 pieces) and remove TCM
from bracket.


Installation
To install, follow the removal steps in reverse order.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-35

Shift Solenoid and Lock-Up Solenoid
Removal
Preparation:

Disconnect negative ( –) battery cable.
 Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove oil lever gage and oil filler tube.
2. Support transfer case (4
4) or rear cover (42)
with a transmission jack.
3. Remove engine rear mounting nuts.


F07RW008
4. Remove fule pipe heat protector on tansmission
corssmenber.
5. Remove fuel pipe from the crossmenber.
6. Remove transmission crossmenber.
7. Remove the nineteen bolts.
8. Remove oil pan, using seal cutter J –37228.



RUW37ASH002901

NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J –37228
Examine particles in oil pan
Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type o
f
wear you will find in the transmission:
Steel (magnetic) ..................bearing, gear and
clutch plate wear
Brass (non-magnetic) ..........bushing wear



240RY00008
9. Remove the oil strainer assembly.



244RY00003

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-37

Valve Body Assembly and Pressure Control Solenoid





244RY00009
Removal
Preparation:


Disconnect negative ( –) battery cable.
 Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove the nineteen bolts and oil pan.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-43

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands.
3. Remove front propeller shaft.(4WD only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
5. Remove the middle exhaust pipe.



RTW37ASH0001

6. Disconnect the transfer harness connectors and the
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
7. Support transfer case with a transmission jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.






P1010010
11. Discinnect the transmission harness connectors
and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.