diesel ISUZU TF SERIES 2004 Repair Manual

MANUAL TRANSMISSION 7B1-77

Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring (5)
from the transmission case.
4. Remove the shift fork, and boot. (Diesel engine,
C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)



RTW47BSH000601

Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002

Legend
(1) Fulcrum bridge
8. Remove the front cover (8) and gasket from the
transmission case.
9. Remove snap ring (7) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (9) fixing top gear bearing.

226RS001
11. Remove gear control box assembly (1).
12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).

MANUAL TRANSMISSION 7B1-79

5. Install top gear bearing snap ring (9) and counter
front bearing snap ring (7).


Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.


The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal (8).
Front Cover Oil Seal Replacement


Remove the oil seal from the front cover.


Apply engine oil to a new oil seal outer
circumference.

Apply recommended grease to the oil seal lip.


Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R3000020
8. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (6).
(Diesel engine, C24NE)
F07L100026
9. Install the fulcrum bridge to the transmission case.
(6VE1)
Torque: 38 N




m (3.9 kg




m/28 lb




ft)
RTW37ASH0002

Legend
(1) Fulcrum bridge

10. Apply molybdenum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
(6VE1)
11. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)

11A-4 IMMOBILIZER SYSTEM

Diesel Engine With ECM (4JH1-TC/4JA1-TC)

LTW3BALF000201

IMMOBILIZER SYSTEM 11A-5

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)






RAW4B0LF000101

11A-8 IMMOBILIZER SYSTEM

Diesel Engine With ECM (4JH1-TC/4JA1-TC)


RTW4B0LF000101

IMMOBILIZER SYSTEM 11A-9

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)






RAW4B0LF000401

11A-32 IMMOBILIZER SYSTEM

Diagnostic Trouble Code (DTC) list with ECM





Immobilizer Control Unit (ICU)
DTC
Description Note
B0001
REPLACE ELECTRONIC CONTROL UNIT
(ECU) (IMMOBILIZER FAULT) This error code appears if a RAM /ROM Error was
detected or the EEPROM is defect.
B0002 IMMOBILIZER NOT PROGRAMMED Immobilizer control unit is not programmed.
B0003 TRANSPONDER KEY PROBLEM

Reading of Transponder information failed with ignition
on transponder has a fault.


Hardware fault in reading circuit.
B0004
IMMOBILIZER COIL CIRCUIT (ANTENNA
COIL FAULT) Immobilizer coil has a fault.
B0005 COMMUNICATION LINE W VOLTAGE LOW Short circuit to ground or open circuit.
B0006 COMMUNICATION LINE W VOLTAGE HIGH Short circuit to 12V.
B0007 NO ENGINE REQUEST RECEIVED No ECM Challenge.
B0008 WRONG TRANSPONDER KEY Incorrect security code response received.
B0009 NO TRANSPONDER KEY PROGRAMMED Transponder security code table empty
B0010 UNKNOWN TRANSPONDER KEY Transponder security code not valid.






Engine Control Module (ECM: Gasoline Engine {6VE1, C24SE})

DTC Description
Note
P1626 No Response From Immobilizer Refer to Engine Control system section
P1631 Received Response Was Not Correct Refer to Engine Control system section
P1648 Received Incorrect Security Code Refer to Engine Control system section
P1649 Security Code & Security Key Not
Programmed Refer to Engine Control system section






Engine Control Module (ECM: Diesel Engine {4JH1-TC, 4JA1-TC})

DTC Description Note
P1610 Seeds and Key File Destroyed Refer to Engine Control system section
P1611 Wrong Security Code Entered Refer to Engine Control system section
P1612/
P1613 Immobilizer No or Wrong Signal Refer to Engine Control system section
P1649 Wrong Transponder Key Refer to Engine Control system section

IMMOBILIZER SYSTEM 11A-33

Diagnostic Trouble Code (DTC) list with Engine Immobilizer Unit (4JA1-T Diesel Engine)





Engine Immobilizer Unit
Code
(DTC) Description Detecting Condition
B0011 TRANSPONDER KEY PROBLEM Transponder code unsuccessfully read 5 consecutive
time. (No completely read in 500ms transponder code)
B0012 WRONG TRANSPONDER KEY Immobilizer program no executed.
B0013 IMMOBILIZER NOT PROGRAMMED Processing program no executed.
B0014 NO TRANSPONDER KEY PROGRAMMED Processing to save the transponder key in the control unit
not Executed.
B0015 FREQUENCY SIGNAL Lo Lo level (less than 2.5) input during the Hi level was being
output to the communication line.
B0016 FREQUENCY SIGNAL Hi (Diesel) Hi level (more than 2.5v) input during the Lo level was
being output to the communication line.
B0023 ANTENNA COIL OPEN Antenna coil not connected.
B0024 WRONG TRANSPONDER RESPONSE Transponder response signal with challenge is wrong.
B0055 EEPROM ERROR Write and read cannot be correctly made to and from the
EEPROM in the control unit.

TRANSFER CASE 7D-11

Transfer Disassembly

RTW47DLF000101
Legend


(7) Neutral Switch ASM
(1) Transfer Case

(8) Speedometer Bush, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut

(9)Transfer Actuator
(3) Stoneguard

(10)Breather Hose
(4) Detent Plug, Spring and Detent Ball

(11) Heat Protector (Except Diesel Engine)
(5) 2-4 Switch ASM


(6) Switch Bracket



Removal
1.
Remove the stoneguard.
2.
Remove the drain plug from the transfer case to
drain the oil.
3.
Remove the parts listed below.


Speedometer bush, plate, and speedomete
r
driven gear


Breather hose (Between the transfer case and
the transfer actuator assembly)


Transfer actuator assembly


Switch bracket