check oil ISUZU TF SERIES 2004 Repair Manual

7C-42 CLUTCH

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage

CLUTCH 7C-43

1. CLUTCH SLIPPAGE

Checkpoint
Trouble Cause
Countermeasure


Adjust the push rod play

No push rod play in the master
cylinder
NG
Clutch pedal free play

Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal

Clean the related parts and/or
replace the facing


Repair or replace the
transmission front cover


Defective transmission front
cover oil seal

Continued on the next page

Grease or oil adhering to the
facing

Too much grease


Transmission front cover
unevenly worn


Clean and grease the release
bearing

Release bearing

Insufficient grease on the front
cover contact surfaces

NG NG NG NG OK
OK
OK

7C-44 CLUTCH

Checkpoint Trouble Cause Countermeasure

Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG NG
OK OKGrease or oil adhering to the
facing
Clutch diaphragm springReplace the clutch pressure
plate assemblyWeak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG NG
OKFacing Continued from the previous page

CLUTCH 7C-47

3. CLUTCH SHUDDER

Checkpoint
Trouble Cause
Countermeasure

Grease or oil adhering to the
facing
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Replace the pressure plate
assembly
Defective transmission front
cover oil seal
Pressure plate unevenly wornPressure plate
Clean the related parts and/or
replace the facing
Tighten the connections
Repair or replace the
applicable parts
Too much grease
Poorly connected components
causing looseness and
abrasion
OK
NG NG NG NG
OK
Power train
Clean and grease the spline
contact surface
Insufficient grease on the
spline contact surface of the
splined hub
Driven plate
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Corrosion or step wear on the
top gear shaft spline
Defective crankshaft rear oil
seal
OKNG NG NG
OK
Continued on the next page

7C-50 CLUTCH

5. OIL LEAKAGE

Checkpoint
Trouble Cause
Countermeasure


Replace the body sub
assembly
Weak or damaged piston cup
NG

Tighten the oil pipe


Tighten the oil pipe connection


Tighten the fluid pipe and/or
hose connections


Fluid reservoir

Loosely connected oil pipe


Loosely connected oil pipe


Master cylinder fluid pipe and
hose

Loosely connected fluid pipe
and/or hose


Slave cylinder oil pipe


Replace the piston cup

Slave cylinder

Weak or damaged piston cup

NG NG NG NG
OK OK
OK
OK

Master cylinder

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green

ELECTRICAL-BODY AND CHASSIS 8A-261
2. Even when the parking brake lever is pulled, the indicator light does not go off

Checkpoint Trouble Cause Countermeasure

Adjust the SW. installation
position or replace the parking
brake SW. Incorrect the parking brake
SW. adjustment or brake SW.
faulty
NG Thermo unit malfunction
Replace the brake fluid level
SW., or vacuum SW., or
repair a short circuit between
the parking brake SW.
connector 1
C-39
(Lever: 1
R-4) and 9 B-23
or the brake fluid level SW.
connector 2
C-37 and 9
B-23, (or the vacuum SW.
connector 1
C-38 and 9
B-23 : 4JH1-TC ONLY)
Check to see if the indicator
light goes off when the parking
brake SW. connector 1
C-39
(Lever: 1
R-4) is
di t d
Brake fluid level SW. or
vacuum SW. faulty or short
circuit
NG OK

Parking brake SW. installation
position and function




3. Oil pressure warning light does not go off while engine is running


Refer to ENGINE Section

Refer to ENGINE Section
NG Thermo unit malfunction

Repair a short circuit between
1
E-1 and 3 B-24

Check to see the warning light
goes off when the oil pressure
SW. connector
1
E-1 is disconnected


Short circuit


Replace the oil pressure unit
(or the oil pressure SW.)
Continuity between the oil
pressure SW. connector
1
E-1 and the body ground
when the engine is operating


Oil pressure unit (or oil
pressure SW) faulty
NG NG OK
OK

Engine oil pressure

8A-274 ELECTRICAL-BODY AND CHASSIS





Terminal Connector No. B-23
No. C24SE
1
ABS CONT. (BRAKE)
2


3


4


5


6


7


8


9
BRAKE
10
CHARGE
11
TURN (RIGHT)
12


13


14


15


16


17
ILLUMI (-)
18
ILLUMI (+)

Terminal Connector No. B-24
No. C24SE
1


2
4LO
3
OIL PRESSURE
4


5
4WD
6
CHECK 4WD
7


8


9
SPEED (+)
10
4P OUTPUT
11


12
STARTER
13
TEMP
14
FUEL
15
FRONT FOG
16


17
CHECK ENGINE
18
AIR BAG
19
SEAT BELT
20
BEAM (+)
21
TURN (LEFT)
22
BEAM (-)
23
BEAM (+)
24


25


26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN

ELECTRICAL-BODY AND CHASSIS 8A-275







Connector No. B-23
Terminal Connector place SOUTH
AFRICA SAUDI
ARABIA ISRAEL EC UK OTHER
1
ABS CONT. (BRAKE)
2
CHECK TRANS
3
A/T-P
4
A/T-R
5
A/T-2
6
A/T-L
7








8








9
BRAKE
10
CHARGE
11
TURN (R)
12
A/T-N
13
A/T-D
14
A/T-3
15
DIFF. LOCK





16
A/T OIL TEMP


17
ILL (-)
18
ILL (+)



RTW48AXF005901

8A-276 ELECTRICAL-BODY AND CHASSIS


Connector No. B-24
Terminal Connector place SOUTH
AFRICA SAUDI
ARABIA ISRAEL EC UK OTHER
1
SEDIMENTER
2
4LO
3
OIL PRESS
4
4WD
5
CHECK 4WD
6
GLOW
7
POWER DRIVE
8








9
SPEED (+)
10
4P OUTPUT
11
TACHO
12
STARTER
13
TEMP
14
FUEL
RR FOG


15
FRONT FOG






16
ABS CONT. (ABS)
17
CHECK ENGINE
18
AIR BAG
SEAT BELT 19
LOW COOLANT





CRUISE SET



20
BEAM (+)




21
TURN (LEFT)
22
BEAM (-)
BEAM (+)


23
FRONT FOG




24
3rd START (A/T)
25








26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN