engine oil 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 4125 of 4264
DIAGNOSIS (JR405E) 7A2-133
No. G4: Large Noise During Idling with the Vehicle in Stop State
Description:
The transmission is noisy during the idling speed in all ranges.
Diagnosis Hints:
Causes such as solenoid operating sound or faulty oil pump are considered.
Distinguishing to some extent is possible by stopping the solenoid operation temporarily, checking the correlation
for the former case and, changing the line pressure and confirming the correlation with noise.
As a matter of course, noise may be generated around the engine, for instance, other than the AT and should be
checked carefully.
Note:
When the noise is generated only at the time of gear shift, it may be the sound of flowing ATF or gear
noise. If the sound varies depending on the gear speed to be shifted, it may be the gear noise generated
from the planetary gear and its related components. If the sound varies depending on the vehicle
speed, it may be the gear noise of the output system, and if varying depending on the engine speed, it
may be the gear noise of the input system or faulty torque converter.
In either case, sound may be "noise" depending on the origin and resonance object. When the object
generating the sound (resonance object) and the sound source (vibration source) are different,
investigation of the cause may be difficult.
No. H1: Judder Occurs at the Lock-up
Diagnosis Hints:
The vehicle body judders at lock-up.
Diagnosis Hints:
Slip due to burning of the lockup piston or insufficient fastening due to dropped working pressure are considered.
Trouble diagnosis flow is basically the same as "No. I1: No lock-up".
Note:
When the lock-up piston has burnt, foreign material mixed in the oil cooler is considered. In such a
case, inspect the oil cooler circuit for clogging of the oil cooler.
No. H2: Large Lock-up Shock
No. H3: Lock-up Point is High or Low
Description:
Large shock is felt at lock-up.
Lock-up point is excessive high or low.
Diagnosis Hints:
Out of properties of input sensor or faulty lock-up piston pressure system are considered.
Trouble diagnosis flow is basically the same as "No. I1: No lock-up".
Page 4128 of 4264
7A2-136 DIAGNOSIS (JR405E)
No. J1: Oil Leaks from Breather
Description:
Oil leaks from breather.
Possible Cause:
ATF quantity is excessively.
No. J2: Oil Leaks Between Engine and Converter Housing
No. J3: Oil Leaks Between Main Case and Converter Housing
No. J4: Oil Leaks Between Main Case and Rear Housing
No. J5: Oil Leaks from Oil Pan
No. J6: Oil Leaks from Manual Shaft Oil Seal
No. J7: Oil Leaks from Oil Cooler Pipe Joint
Description:
Oil leaks between engine and converter housing.
Oil leaks between converter housing and main case.
Oil leaks between main case and rear housing.
Oil leaks from oil pan.
Oil leaks from manual shaft oil seal.
Oil leaks from oil cooler pipe joint.
Possible Cause:
Faulty oil seal or sealing of contact surface is considered.
No. Z1: Transmission Overheat
Description:
You smell the transmission burning.
The transmission smokes.
Possible Cause:
Slip of clutch.
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Clogged oil cooler (foreign substance mixed)
ATF stirred excessively (too much ATF).
Faulty torque converter operating pressure.
Faulty lock-up piston.
Page 4130 of 4264
7A2-138 DIAGNOSIS (JR405E)
No. Z6: Poor Fuel Consumption
Description:
Poor fuel consumption.
Diagnosis Hints:
Basically same causes as "No. C1 - C8: Engine races up (slip) by shift up or shift down" are considered.
No. Z7: Pattern Select Switch is Faulty
Description:
Shift pattern does not change though the pattern select switch is turned on.
Possible Cause:
Faulty mode select switch is considered.
No. Z8: Oil is Splashed During the Running
Description:
Oil is splashed during the running
Possible Cause:
ATF quantity is too high.
No. Z9: Abnormal Smell
Description:
Abnormal smell.
Diagnosis Hints:
Basically a trouble in the AT main unit.
No. Z10: ATF Quantity is Low or High
Description:
Oil quantity is low or high.
Possible Cause:
In case of oil level is high.
ATF temperature is low when ATF quantity is checked.
In case of oil level is low.
ATF leaks is considered. Check the AT main unit and cooler circuit.
Page 4131 of 4264
DIAGNOSIS (JR405E) 7A2-139
No. Z11: Abnormal Oil Pressure
Description:
Oil pressure is low or high.
Possible Cause:
Basically, the same cause as "No. C1 - C8: Engine races up (slip) by shift up or shift down" is considered.
In case of oil pressure is low, faulty oil pump is considered.
No. Z12: Reverse Buzzer Does Not Ring
Description:
Reverse buzzer does not ring in R range.
Possible Cause:
Disordered select cable.
Disordered select lever.
Disordered inhibitor switch.
Page 4132 of 4264
7A2-140 DIAGNOSIS (JR405E)
STALL TEST
CAUTION:
Because A/T may break down, do not perform the stall test continuously.
Procedure
1. Chock the four wheels.
2. Warm up the engine.
3. Apply the parking brake.
4. Step on the foot brake fully.
5. Set the select lever to either D, 3, 2, L or R range.
6. Step on the accelerator pedal fully.
7. When the engine speed becomes constant, record tha
t
value quickly.
Stall Speed
Standard: 2600±150 rpm
Evaluation
1. If the stall speed is higher than standard value in all
ranges.
Low line pressure.
Abraded oil pump.
Faulty operation of low clutch.
Adjustment error of or faulty inhibitor switch.
ATF leaking from oil pump, control valve, or
transmission case.
Fixed pressure regulator valve and pilot valve.
2. If the stall speed is higher than standard value in D, 3, 2
and L ranges.
Slip of low clutch.
Slip of low one-way clutch.
3. If the stall speed is higher than standard value in
R
range.
Slip of low & reverse brake.
Slip of reverse clutch.
4. If the stall speed is lower than standard value in all
ranges.
Slip of one-way clutch (in torque converter).
Faulty engine.
Page 4133 of 4264
DIAGNOSIS (JR405E) 7A2-141
LINE PRESSURE TEST
Procedure
1. Chock the four wheels.
2. Remove the test plug of the transmission case and fit the oil
pressure gauge.
3. Warm up the engine.
4. Apply the parking brake.
5. Step on the foot brake fully.
6.Set the select lever to either D, 3, 2, L or R range.
7. Record the oil pressure at idling.
8. When stepping over the accelerator pedal fully and the
engine speed becomes constant, record the oil pressure
quickly.
Line Pressure
Standard:
Engine Line Pressure (Kpa)
Speed D, 3, 2 or L Range R Range
Idling 350 - 480 450 - 650
Stall 1,050 - 1,250 1.400 - 1,630
Evaluation
1. If the line pressure is lower than standard value at
idling in all ranges.
Abraded oil pump.
Faulty operation of each solenoid.
Sticking of pressure regulator valve or pilot valve.
Fatigued pressure regulator valve or pilot valve spring.
ATF leaking from oil strainer, oil pump, pressure
regulator valve, torque converter relief valve or pressure
relief valve.
2. If the line pressure is lower than standard value at
idling in D, 3, 2 and L ranges.
ATF leaking from low clutch hydraulic circuit.
3. If the line pressure is lower than standard value at
idling in R range.
ATF leaking from reverse hydraulic circuit.
ATF leaking from low and reverse brake hydraulic
circuit.
Page 4135 of 4264
DIAGNOSIS (JR405E) 7A2-143
TIME LAG TEST
Procedure
1. Chock the four wheels.
2. Warm up the engine.
3. Apply the parking brake.
4. Step on the foot brake fully.
5. Set the select lever from N to D or N to R range.
6. Record the time from when moving the select button until
feeling shock.
Time Lag
Standard:
N to D Range: Below 0.7 Seconds
N to R Range: Below 1.2 Seconds
Evaluation
1. If the time lag is out of standard value when shifting N
to D range.
Forward range line pressure is low.
Slip of low clutch.
Slip of low one-way clutch.
Trouble in control valve body (faulty operation, sticking,
clogged oil passage).
Faulty low clutch duty solenoid operation.
Shortage or faulty quality of ATF.
2. If the time lag is out of standard value when shifting N
to R range.
Reverse range line pressure is low.
Slip of low & reverse brake.
Slip of reverse clutch.
Trouble in control valve body (faulty operation, sticking,
clogged oil passage).
Faulty low & reverse brake duty solenoid operation.
Shortage or faulty quality of ATF.
Page 4147 of 4264
DIAGNOSIS (JR405E) 7A2-155
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
Related
harness
Engine
Speed
Sensor A7 BLK/
RED Engine Speed Sensor Input ECM Voltage (Wave
form) At 2000rpm.
Circuit tester
(+) to A7 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.2V)
ECM
A8 - - - - - - - -
A9 - - - - - - - -
Related
harness
Speed
sensor
Speed meter
A10 BLK/
YEL Vehicle Speed Sensor Out (2WD Only) Output Speed meter Voltage (Wave
form) At run in L
range in 1st
gear 20 km/h.
Circuit tester
(+) to A10 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.5V)
TCM
At switch
pushed Less than 2VRelated
harness
A11 GRN/
WHT 3rd Start Select Switch Input 3rd start switch Voltage
At switch off 10 – 14.5V 3rd start
switch
At 4L Less than 2VRelated
harness
A12 BLU/
WHT 4L Mode Switch (4WD Only) InputTransfer control
unit Voltage
At other than
4L 10 – 14.5V 4L switch
A13 - - - - - - - -
A14 - - - - - - - -
A15 - - - - - - - -
At fully close Off duty 10%Related
harness
ECM A16 RED/
WHT Throttle Position Sensor Input ECM Wave form
(140Hz Duty
signal) *1
At fully open Off duty 90%Throttle
position
sensor
At 3 range 10 – 14.5V Related
harness
A17 BLK/
GRN 3 Range Switch Input Inhibitor switch Voltage
At other than
3 range Less than 2VInhibitor
switch
At key switch
ON 10 – 14.5V Related
harness
A18 YEL/
BLK DIAG Switch InputData link
connector Voltage
At short circuit
of DIAG
switch Less than 2VRelated
harness
At lamp OFF 10 – 14.5V Related
harness A19 ORG/
BLU A/T OIL TEMP Indicator Lamp OutputAT OIL TEMP
indicator lamp Voltage
At lamp ON Less than 2V Lamp
At lamp OFF 10 – 14.5V Related
harness A20 GRN/
YEL CHECK TRANS Indicator Lamp OutputCHECK TRANS
indicator Lamp Voltage
At lamp ON Less than 2V Lamp
At lamp OFF 10 – 14.5V Related
harness A21 PNK POWER DRIVE Indicator Lamp OutputPOWER DRIVE
indicator lamp Voltage
At lamp ON Less than 2V Lamp
A22 - - - - - - - -
A23 - - - - - - - -
Page 4155 of 4264
ON-VEHICLE SERVICE (JR405E) 7A3-3
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20C (68F) 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 40-50C
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
Page 4171 of 4264
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.