brake ISUZU TF SERIES 2004 Workshop Manual

DIAGNOSIS (JR405E) 7A2-145

5. R range test.
1) Shift into the R range and while starting at full throttle,
check for slipping.
6.P range test.
1) Stop the vehicle on a grade and after shifting into the P
range, release the parking brake. Then check to see tha
t
the parking lock pawl holds the vehicle in place.


Select
Lever
Position
Gear
Position
Gear
Shift
P










R Reverse





N










D 1st
2nd
3rd
4th
3 1st
2nd
3rd
4th(*1)
2 1st
2nd
3rd(*1)
4th(*1)
L 1st
2nd(*1)
3rd(*1)
4th(*1)
Evaluation
1. If there is no 1 to 2 up-shift.

2-4 brake malfunction.

2-4 brake hydraulic circuit failed.

2-4 brake duty solenoid stick.
Refer to symptom diagnosis "No. D1: Faulty Gea
r
Shifting" or DTC section "Gear Ratio Error".

2. If there is no 2 to 3 up-shift.

High clutch malfunction.

High clutch hydraulic circuit failed.

High clutch duty solenoid stick.
Refer to symptom diagnosis "No. D1: Faulty Gea
r
Shifting" or DTC section "Gear Ratio Error".

3. If there is no 2 to 4 (O/D) up-shift.

2-4 brake malfunction.

2-4 brake hydraulic circuit failed.

2-4 brake duty solenoid stick.
Refer to symptom diagnosis "No. D1: Faulty Gea
r
Shifting" or DTC section "Gear Ratio Error".

4. If there is no lock-up in 2, 3 and 4.

Lock-up piston malfunction.

Lock-up hydraulic circuit failed.

Lock-up duty solenoid stick.
Refer to symptom diagnosis "No. I1: No Lock-up"o
r
DTC section "Lock-up Duty Solenoid Failure".


*1: Transmission is shifted at high speed to
prevent engine over-run.

7A2-146 DIAGNOSIS (JR405E)

5. If there is no reverse.

Reverse clutch malfunction.

Reverse clutch hydraulic circuit failed.

Low & reverse brake hydraulic circuit failed.

Low & reverse brake duty solenoid stick.
Refer to symptom diagnosis "No. A2: Vehicle Dose Not
Run in R Range" or DTC section "Low & Reverse
Brake Duty Solenoid Failure".
6. If there is no parking.

Parking pawl malfunction.
Refer to symptom diagnosis "No. G1: Vehicle Moves in
P Range or Parking Gear in Not Disengaged othe
r
than P Range".

NOTE:
The check for the cause of abnormal noise and vibration
must be made with extreme care as it could also be due to
loss of balance in propeller shaft, differential, the torque
converter, etc. Or insufficient bending, rigidity, etc. in the
powertran.

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 - - - - - - - -

7A2-156 DIAGNOSIS (JR405E)
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
At lamp OFF 10 – 14.5V Related
harness A24 GRN/
YEL Power Drive Select Switch InputPower drive
switch Voltage
At lamp ON Less than 2V Lamp
At other than
2nd or 4th
gear More than 10
V Related
harness
B1 RED/
YEL 2-4 Brake Pressure Switch Input2-4 brake
pressure switch Voltage
At 2nd or 4th
gear Less than 2VPressure
switch
At 2 range 10 – 14.5V Related
harness
B2 PNK/
BLK 2 Range Switch Input Inhibitor switch Voltage
At other than
2 range Less than 2VInhibitor
switch
InputRelated
harness
B3 BRN/
RED Turbine Sensor

Turbine sensor Voltage (Wave
form) At run in L
range in 1st
gear 20 km/h.
Circuit tester
(+) to B3 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.5V)Turbine
sensor
ATF temp.
20
C Approx. 1.55
V Related
harness
B4 BLU ATF Thermo Sensor InputATF thermo
sensor Voltage
ATF temp.
60
C Approx. 0.7VThermo
sensor
B5 BLK Ground - Ground Voltage Normally Less than 2VRelated
harness
Related
harness
B6 BLU/
BLK Low & Reverse Brake Duty Solenoid OutputLow & reverse
brake duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B6 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B7 BLK/
YEL 2-4 Brake Duty Solenoid Output2-4 brake duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B7 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B8 RED High Clutch Duty Solenoid OutputHigh clutch duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B8 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B9 WHT/
RED Low Clutch Duty Solenoid OutputLow clutch duty
solenoid Voltage (Wave
form) 4th gear in D
range. Circuit
tester (+) to
B9 pin, (-) to
B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
At N range 10 – 14.5V Related
harness
B10 RED/
BLK N Range Switch Input Inhibitor switch Voltage
At other than
N range Less than 2VInhibitor
switch
At D range 10 – 14.5V Related
harness
B11 BLU D Range Switch Input Inhibitor switch Voltage
At other than
D range Less than 2VInhibitor
switch

DIAGNOSIS (JR405E) 7A2-157
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
At other than
R range, L
range 1st gear More than 10
V Related
harness
B12 YEL Low & Reverse Brake Pressure Switch InputLow & reverse
brake pressure
switch Voltage
At R range, L
range 1st gear Less than 2VPressure
switch
Related
harness
B13 YEL/
RED Vehicle Speed Sensor InputVehicle speed
sensor Voltage (Wave
form) At run in L
range in 1 st
gear 20 km/h.
Circuit tester
(+) to B13 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.8V)Vehicle
speed sensor
B14 BLU/
BLK ATF Thermo Sensor Ground - ATF thermo
sensor Continuity Normally Continuity Related
harness
B15 BLK Ground - Ground Voltage Normally Less than 2VRelated
harness
B16 - - - - - - - -
At lock-up.
Circuit tester
(+) to B17 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 2.2 -
9.0V) Related
harness
B17 BLK Lock-up Duty Solenoid OutputLock-up duty
solenoid Voltage (Wave
form)
At unlock-up.
Circuit tester
(+) to B17 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 1.0 -
2.0V) Duty solenoid
At key switch
ON 10 – 14.5V Related
harness
B18 WHT V ign (Ignition Power Supply) Input Key switch Voltage
At key switch
OFF Less than 2V Fuse
At R range 10 – 14.5V Related
harness
B19 RED/
YEL R Range Switch Input Inhibitor switch Voltage
At other than
R range Less than 2VInhibitor
switch
At other than
3rd or 4th
gear More than 10
V Related
harness
B20 WHT/
BLK High Clutch Oil Pressure Switch InputHigh clutch
pressure switch Voltage
At 3rd or 4th
gear Less than 2VPressure
switch
At L range 10 – 14.5V Related
harness
B21 PNK/
BLK L Range Switch Input Inhibitor switch Voltage
At other than
L range Less than 2VInhibitor
switch
B22 GRY/
RED Ground Return Output Shift solenoid Continuity Normally Continuity Related
harness
At N range 10 – 14.5V Related
harness
B23 VIO Line Pressure Solenoid OutputLine pressure
solenoid Voltage
At D range
stall Less than 2V Solenoid

DIAGNOSIS (JR405E) 7A2-159
Low & Reverse Brake Duty Solenoid Reference Wave Form
Measurement Terminal: B6 (+) B22 (-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: P, N range in idle
0V2-4 Brake Duty Solenoid Reference Wave Form
Measurement Terminal: B7 (+) B22 (-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: P, N range in idle
0V
High Clutch Duty Solenoid Reference Wave Form
Measurement Terminal: B8 (+) B22 (-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: P, N range in idle
0VLow Clutch Duty Solenoid Reference Wave Form
Measurement Terminal: B9 (+) B22 (-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: D range 4th gear
0V
Lock-up Duty Solenoid Reference Wave Form
Measurement Terminal: B17 (+) B5 (-)
Measurement Scale: 10V/div 5ms/div
Measurement Condition: Unlock-up condition
0VLock-up Duty Solenoid Reference Wave Form
Measurement Terminal: B17 (+) B5 (-)
Measurement Scale: 10V/div 5ms/div
Measurement Condition: Lock-up condition
0V

7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.



AUTOMATIC TRANSMISSION FLUID (ATF)
Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch band
and other parts.
The transmission control module, the transmission unit,
and the vehicle must be carefully checked if gum or
varnish is present.




ATF LEVEL
Inspect
Hot Level
1. Warm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80
C (176
F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each gear range just long enough for the
transmission to engage.
5. Return the select lever to either “P” or “N”.
C07RW009
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 “H” range on the
dipstick.
242R300001
If the ATF level is below the “H” range, ATF must be
added.

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

7A3-16 ON-VEHICLE SERVICE (JR405E)
SOLENOIDS, OIL PRESSURE SWITCH AND OIL TEMPERATURE
SENSOR
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure switch connector
(wire color: White)
4. Low and reverse brake duty solenoid connector
(wire color: Pink and White)
5. High clutch duty solenoid connector
(wire color: Green and Gray)

6. Lock-up duty solenoid connector
(wire color: Yellow and Black)
7. 2-4 brake duty solenoid connector
(wire color: Blue and Brown)
8. Low clutch duty solenoid connector
(wire color: Orange and Black)
9. Line pressure solenoid connector
(wire color: Pink)

UNIT REPAIR (JR405E) 7A4-7

16ASSY047

11.High clutch hub, bearing, and bearing race

Remove the clutch hub, bearing (with bearing race),
and the bearing race.

Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.

Inspect the bearing race surfaces for damage.



17ASSY040

12.Front sun gear, bearing, and bearing race

Remove the bearing, the front sun gear, and the bearing
race.

Remove the bearing and the bearing race from the fron
t
sun gear.

Inspect the bearing race surfaces for damage.


19ASSY113

13.2-4 brake retainer

Remove the brake seal ring and the sleeve.



23ASSY030



Attach the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0



24ASSY029



Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.

Remove the spring compressor.