service ISUZU TF SERIES 2004 Workshop Manual

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

7A3-2 ON-VEHICLE SERVICE (AW30 –40LE)

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

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)

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.

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

7A3-6 ON-VEHICLE SERVICE (AW30 –40LE)

Diagnosis
Basic Troubleshooting
AW30
–40LE transmission, with Transmission Control
Module (TCM), differs from the Mechanical – Hydraulic
control type transmissions. Accordingly, its
troubleshooting procedure differs also.
Before troubleshooting an TCM, first determine whethe
r
the problem is electrical or mechanical. To do this, just
refer to the basic troubleshooting flowchart provided
below.

If the cause is already known, using the basic
troubleshooting chart below along with the
troubleshooting chart should speed the procedure.




F07R200005-X

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-7

Troubleshooting Chart
Numbers are arranged in order of probability.
Perform inspections starting with number one and
working up.

7A3-8 ON-VEHICLE SERVICE (AW30 –40LE)

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-9

7A3-10 ON-VEHICLE SERVICE (AW30 –40LE)