switch ISUZU TF SERIES 2004 Workshop Manual

7D1-42 TRANSFER CONTROL SYSTEM
Cannot shift from 2WD to 4H or 4L.

When shifting from 2H to other position, the indicator (4WD, 4Lo, Check4WD, neutral)
does not respond.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Failed operation switch. Only 2H
is stuck at ON condition and 4H-
4L position is internally
disconnected. Or,
Failed controller Indicator lamp burnt out.
Disconnected harness wire .
After repairing, trace this chart
from the beginning.


Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10
seconds.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 3. Indicator lamp burnt out.
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 After 2 seconds, check that the
Check4WD lamp is ON or OFF.
Is the Check4WD lamp OFF? Go to step 4. Failed actuator position detection
switch (LS1, LS2, LS3, LS4,
GND).
Short or disconnection of harness
of this detection switch.
After repairing, trace this chart
from the beginning.
4 Press the 4H button.
Is sound of relay heard from the
transfer control? Go to step 5. Failed controller.
Replace the controller and trace
this chart from the beginning.
5 Is the sound of running motor
heard? Failed control system of the
transfer mechanism. Check and
repair and trace this chart from
the beginning. Failed actuator motor.
Disconnected controller motor
drive output circuit, GND short
circuit. +B fuse blown out.
Disconnection of that harness.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)

TRANSFER CONTROL SYSTEM 7D1-43
Even after the correction step 1-2(*), the 4WD indicator still blinks at 2Hz when shifting
from 2H to 4H.
Step Action Yes No
1 Check the air pressure and wear
of all the tires. Is any trouble
noticed? After adjusting the air pressure
and repairing the tire worn away,
try the correction step 1-2(*). Go to step 2.
2 Check the 4WD detection switch
on the transfer case, neutral
detection switch and each
harness. Is a trouble noticed? 4WD detection switch is open or
the harness failed.
The neutral detection switch is
closed or the harness GND is
shorted.
Replace or repair and then trace
this chart from the beginning. Go to step 3.
3 Is there continuity in the harness
between the transfer controller
and front axle actuator? Isn’t a
body short or disconnection
noticed? Go to step 4. Body short or disconnection of
the harness between the transfer
controller and front axle actuator.
After repairing, trace this chart
from the beginning.
4 Is a trouble noticed in the axle
detection harness between the
axle actuator and transfer
controller? Disconnected harness.
After repairing trace this chart
from the beginning. Malfunction of axle actuator.
Refer to the paragraph of the
axle disconnect.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)
Note:
The vehicle of manual hub and rigid hub don’t have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and
the axle switch input terminal of transfer controller instead of axle actuator.

TRANSFER CONTROL SYSTEM 7D1-45
Transfer cannot shift to a position other than 4H.
When shifting from 4H to other position, indicator (4WD, 4Lo, Check4WD, neutral) does
not respond (Only 4WD keeps lighting).
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Failed 4WD indicator and
harness.
After repairing, trace this chart
from the beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON?
Then, only 4H lights up. Go to step 3. Indicator lamps other than the
4WD indicator are burnt out.
(Check for GND short circuit
between the 4WD indicator and
transfer controller.)
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 Press the 2H button.
Is the sound of relay heard from
under the seat, and the sound of
running motor heard? Failed controller.
After replacing the controller,
trace this chart from the
beginning. *Failed operation switch. Or
disconnected or shorted of the
harness for the operation switch.
* The operation switch is an analog type switch which reads the internal composite resistance value at the time of
operation. If an abnormal value is detected, it is judged to be an instruction to 4H.

7D1-46 TRANSFER CONTROL SYSTEM
Even after the correction step 2-1(*), the 4WD indicator still blinks at 2Hz when shifting
from 4H to 2H.
Step Action Yes No
1 Check all the tires for air
pressure and wear. Is any
trouble noticed? After adjusting the air pressure
and repairing the tire worn away,
try the correction step 2-1(*). Go to step 2.
2 Check the 4WD detection switch
on the transfer case and neutral
detection switch and each
harness. Is a trouble noticed? 4WD detection switch is closed
or the GND short of harness.
The neutral detection switch is
closed or the harness GND is
shorted.
Replace or repair and then trace
this chart from the beginning. Go to step 3.
3 Is there continuity in the harness
between the transfer controller
and axle actuator?
Isn’t short or disconnection
noticed?
Isn’t the connection mistaken? Go to step 4. Body short, disconnection or
incorrect connection of the
harness between the transfer
controller and actuator.
After repairing, trace this chart
from the beginning.
4 Is a trouble noticed in the axle
detection harness between the
axle actuator and transfer
controller? GND short of harness Malfunction of axle actuator.
Refer to the paragraph of axle
disconnect.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)

Note:
The vehicle of manual hub and rigid hub don’t have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and
the axle switch input terminal of transfer controller instead of axle actuator.

TRANSFER CONTROL SYSTEM 7D1-47
Though the indicator responds when shifting from 4H to 2H(or other position), it returns
to 4H.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 3. Indicator lamp burnt out.
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 After 2 seconds, check if the
Check4WD lamp lights up.
Is the Check4WD lamp OFF? Go to step 4. Failed actuator position detection
(limit) switch (LS1, LS2, LS3,
LS4, GND).
Short or disconnection of harness
of this detection switch.
Refer to paragraph of
Check4WD.
After repairing, trace this chart
from the beginning.
4 Press the 2H button.
Is the sound of relay heard from
the transfer controller? Go to step 5. Failed controller.
Replace the controller and trace
this chart from the beginning.
5 Is the sound of running motor
heart? Failed control system of the
transfer mechanism. Check and
repair and trace this chart from
the beginning. Failed actuator motor.
Disconnection of controller motor
drive output circuit or GND short.
After repairing, trace this chart
from the beginning.
If the motor does not or cannot run at all (stuck transfer mechanism, disconnected motor, failed drive circuit), the
lamp blinks at 4Hz when the position is shifted to other position by pressing the button for more 10 seconds (20
seconds in case of neutral position).

7D1-48 TRANSFER CONTROL SYSTEM
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3. Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace
this chart from the beginning.
3 Shift to 2H.
Can be shifted to 2H and then to
4H? Go to step 4. Refer to the paragraph about
shifting from 2H to 4H.
In particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Shift back to 4H and go to step 5.
5 Start the engine and travel the
vehicle.
Does the speedometer run at
this time? Go to step 6. Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble noticed? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7 Travel the vehicle several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met? Failed controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1
second or maximum 3 minutes
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)

TRANSFER CONTROL SYSTEM 7D1-49
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3. Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace
this chart from the beginning.
3 Can be shifted to 2H and then to
4L? Go to step 4.
(Impossible usually.)
Failed controller In case of Check 4WD, shifting to
2H is possible.
Returning to 4L is impossible.
Refer to the paragraph about
Check4WD.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Press the operation switch of 4L
and go to step 5.
5 Start the engine and travel the
vehicle.
Does the speedometer run at
this time? Go to step 6. Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble noticed? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7 Travel the vehicle several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met? Failed transfer controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1
second or maximum 3 minutes
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)

7D1-50 TRANSFER CONTROL SYSTEM
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz.
Check the function between H and L according to the chart for 4L to 4H instead of check
for the requirements of neutral.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start the
engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3. Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H
(7D1-37).
After taking the remedy, trace
this chart from the beginning.
3 Can be shifted to 2H and then to
4L? Go to step 4.
(Impossible usually.)
Failed controller Refer to the paragraph about
shifting from 2H to 4H.
In particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
In case of Check4WD, shifting to
2H is possible.
Returning to 4H is impossible.
Refer to the paragraph about
Check4WD.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the lamp
blinks at 4Hz after operation. Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Shift back to 4H and go to step 5.
5 Start the engine and travel the
vehicle.
Does the speedometer run at this
time? Go to step 6. Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble noticed? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7 Travel the vehicle several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were met? Failed controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1
second or maximum 3 minutes
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)
For shifting to neutral, 2H and 4L switches should be kept pressed at the same time for 10 seconds.
For shifting from neutral to other position, 2H, 4H or 4L switch should be kept pressed for 10 seconds.
When shifting from neutral to other position, the lamp blinking at 2Hz indicates active condition.
When the lamp keeps blinking at 2Hz, follow the step for the case when the lamp keeps blinking at 2Hz when
shifting between positions.

7A2-8 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

CHECK ITEM PIN No. VALUE NOTE
Shift Solenoid B (S2) A15 –A1 P 0V Engine run.

R 0V Engine run. (Without the
Reverse range lock out)
N 0V Engine run.
D –1 0V

D –2 VIGN

D –3 VIGN

D –4 0V
Lock-up Solenoid A5
–A1 ON VIGN (ex.) It is “ON ” when the
vehicle speed is more than
65km/h.
OFF 0V
Check Trans Lamp B3
–A1 ON 0V Key “ON ”
(The lamp is “ON ” for 3
second after key “ON ”)

OFF VIGN
AT Oil Temperature Lamp B11
–A1 ON 0V Key “ON ”
(The lamp is “ON ” for 3
second after key “ON ”)

OFF VIGN
Power Lamp B2
–A1 ON 0V Key “ON ”
(The lamp is “ON ” when the
Power switch is “ON ”)

OFF VIGN
3 rd Start Lamp B10
–A1 ON 0V Key “ON ”
(The lamp is “ON ” when the
3rd Start switch is “ON ”)

OFF VIGN
AT Oil Temp Sensor
Resistance A11
–A12 20

C
12k
Key “OFF ”

50

C 1.5k

155

C 293

Pressure Control Solenoid
Resistance A4
–A2 About
4 –7

(20

C)
Key “OFF ”
Speed Sensor Resistance B5 –B14 About
560

– 120
(20

C)
Key “OFF ”
Input Revolution Sensor
Resistance B6
–B16 About
560

– 120
(20

C)
Key “OFF ”
Lock-up Solenoid
Resistance A5
–A1 About
10

– 15
(20

C)
Key “OFF ”
Shift Solenoid A (S1)
Resistance A16
–A1 About
10

– 15
(20
C)
Key “OFF ”
Shift Solenoid B (S2)
Resistance A15
–A1 About
10

– 15
(20

C)
Key “OFF ”

7A2-10 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Control and Functions
Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the
gear ratio is controlled by the ON/ OFF signal using the
shift solenoid S1 and the shift solenoid S2.
Band Apply Control
The band apply is controlled when in the 3 –2 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow
of the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch (TCC) solenoid using the ON/OFF
signal.
Line Pressure Control
The throttle signal allows the current signal to be sent
to the force motor. After receiving the current signal,
the force motor activates the pressure regulator valve
to regulate the line pressure.
On –Board Diagnostic System
Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and read
out of it afterward.
The serial data lines, which are required for the testing
of the final assembly and the coupling to othe
r
electronic modules, can be regulated by this function.
Fail –Safe Mechanism
If there is a problem in the transmission system, the
TCM will go into a “backup" mode.
The vehicle can still be driven, but the driver must use
the select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change o
f
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning,
TCC, and the 3rd start mode.
Reverse Lock Out Control
With the selector lever in reverse position, the TCM will
not close the PWM solenoid until the vehicle is below
15 km/h (9.3 mph), thus preventing reverse
engagement above this speed.

Downhill Control
This mode is automatically activated from NORMAL
mode only when downhill conditions are recognized.
The shift pattern is identical to NORMAL mode except
3-4 and 4-3 shift lines at low throttle modified to get
engine braking on a larger speed range.
Uphill Control
When uphill condition are recognized the 2-3 and 3-4
shift and TCC apply are down only when the engine
torque is sufficient in order to avoid shift hunting.
Gear Shift Control 3rd start


SELECT LEVER RANGE SHIFT PATTERN
D(Drive) 1


2TCC

3TCC

4TCC
3(Third) 1

2TCC

3TCC
2(Second) 1

2(
3)
L(First) 1(
2)
TCC: Torque Converter Clutch
(Notice1): “( )" means over-revving prevention control.
Mode Type


Mode Type Select lever position
Normal drive mode
(NOR) Entire range (excluding “R")
Power drive mode
(PWR) Entire range (excluding “R")

Mode Selection



SWITCH(SW) LAMP
Mode Type PWR/N
OR.S 3RD
START SW POWER
DRIVE LAMP 3RD
START LAMP
Normal
drive mode
(NOR) OFF OFF OFF OFF
Power
drive mod
(PWR) ON OFF ON OFF
3rd Start
mode OFF ON OFF ON
However, the 3rd start switch prevails over the
PWR/NOR switch.
The mode become normal drive mode when the 3rd
start switch is operated from ON to OFF.