switch 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 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 4146 of 4264
7A2-154 DIAGNOSIS (JR405E)
TCM VOLTAGE CHECK
TCM voltage check is done to check for transmission and TCM
problems which cannot be detected by self-diagnosis.
Additionally, it severs as a back-up check for self-diagnosis.
Measure the voltage drop and make a continuity test for each of
sensors, solenoids and switches.
If the voltage is within the specified range and continuity exists,
that particular area of the TCM and transmission assembly is
normal.
If voltage deviation or lack of continuity is discovered, disconnect
the applicable parts and check of them individually.
Inspection Tool
Use a circuit tester and an oscilloscope to measure voltage and
circuit continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.
TCM Pin Assignment
Connect to White Connector Connect to Grey Connector
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
A1 RED V BATT (Battery Back-up Power
Supply) Input Battery Voltage - 10 – 14.5V Related
harness
At P range 10 – 14.5V Related
harness
A2 YEL/
VIO P Range Switch Input Inhibitor switch Voltage
At other than
P range Less than 2VInhibitor
switch
At brake
stepped 10 – 14.5V Related
harness
A3 RED Brake Switch Input Brake switch Voltage At brake no
stepped Less than 2V Brake switch
At lamp OFF 10 – 14.5V Related
harness A4 PNK/
WHT 3rd Start Indicator Lamp Output 3rd start lamp Voltage
At lamp ON Less than 2V Lamp
A5 GRN K-line signal (Tech 2 serial
communication) Input/
OutputTech 2 - - - Related
harness
A6 - - - - - - - -
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 4148 of 4264
7A2-156 DIAGNOSIS (JR405E)
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
At lamp OFF 10 – 14.5V Related
harness A24 GRN/
YEL Power Drive Select Switch InputPower drive
switch Voltage
At lamp ON Less than 2V Lamp
At other than
2nd or 4th
gear More than 10
V Related
harness
B1 RED/
YEL 2-4 Brake Pressure Switch Input2-4 brake
pressure switch Voltage
At 2nd or 4th
gear Less than 2VPressure
switch
At 2 range 10 – 14.5V Related
harness
B2 PNK/
BLK 2 Range Switch Input Inhibitor switch Voltage
At other than
2 range Less than 2VInhibitor
switch
InputRelated
harness
B3 BRN/
RED Turbine Sensor
Turbine sensor Voltage (Wave
form) At run in L
range in 1st
gear 20 km/h.
Circuit tester
(+) to B3 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.5V)Turbine
sensor
ATF temp.
20C Approx. 1.55
V Related
harness
B4 BLU ATF Thermo Sensor InputATF thermo
sensor Voltage
ATF temp.
60C Approx. 0.7VThermo
sensor
B5 BLK Ground - Ground Voltage Normally Less than 2VRelated
harness
Related
harness
B6 BLU/
BLK Low & Reverse Brake Duty Solenoid OutputLow & reverse
brake duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B6 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B7 BLK/
YEL 2-4 Brake Duty Solenoid Output2-4 brake duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B7 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B8 RED High Clutch Duty Solenoid OutputHigh clutch duty
solenoid Voltage (Wave
form) P, N range.
Circuit tester
(+) to B8 pin,
(-) to B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
Related
harness
B9 WHT/
RED Low Clutch Duty Solenoid OutputLow clutch duty
solenoid Voltage (Wave
form) 4th gear in D
range. Circuit
tester (+) to
B9 pin, (-) to
B22 pin. Pulse
generated (At
AC range
approx. 6.2V)Duty solenoid
At N range 10 – 14.5V Related
harness
B10 RED/
BLK N Range Switch Input Inhibitor switch Voltage
At other than
N range Less than 2VInhibitor
switch
At D range 10 – 14.5V Related
harness
B11 BLU D Range Switch Input Inhibitor switch Voltage
At other than
D range Less than 2VInhibitor
switch
Page 4149 of 4264
DIAGNOSIS (JR405E) 7A2-157
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
At other than
R range, L
range 1st gear More than 10
V Related
harness
B12 YEL Low & Reverse Brake Pressure Switch InputLow & reverse
brake pressure
switch Voltage
At R range, L
range 1st gear Less than 2VPressure
switch
Related
harness
B13 YEL/
RED Vehicle Speed Sensor InputVehicle speed
sensor Voltage (Wave
form) At run in L
range in 1 st
gear 20 km/h.
Circuit tester
(+) to B13 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 6.8V)Vehicle
speed sensor
B14 BLU/
BLK ATF Thermo Sensor Ground - ATF thermo
sensor Continuity Normally Continuity Related
harness
B15 BLK Ground - Ground Voltage Normally Less than 2VRelated
harness
B16 - - - - - - - -
At lock-up.
Circuit tester
(+) to B17 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 2.2 -
9.0V) Related
harness
B17 BLK Lock-up Duty Solenoid OutputLock-up duty
solenoid Voltage (Wave
form)
At unlock-up.
Circuit tester
(+) to B17 pin,
(-) to B5 pin. Pulse
generated (At
AC range
approx. 1.0 -
2.0V) Duty solenoid
At key switch
ON 10 – 14.5V Related
harness
B18 WHT V ign (Ignition Power Supply) Input Key switch Voltage
At key switch
OFF Less than 2V Fuse
At R range 10 – 14.5V Related
harness
B19 RED/
YEL R Range Switch Input Inhibitor switch Voltage
At other than
R range Less than 2VInhibitor
switch
At other than
3rd or 4th
gear More than 10
V Related
harness
B20 WHT/
BLK High Clutch Oil Pressure Switch InputHigh clutch
pressure switch Voltage
At 3rd or 4th
gear Less than 2VPressure
switch
At L range 10 – 14.5V Related
harness
B21 PNK/
BLK L Range Switch Input Inhibitor switch Voltage
At other than
L range Less than 2VInhibitor
switch
B22 GRY/
RED Ground Return Output Shift solenoid Continuity Normally Continuity Related
harness
At N range 10 – 14.5V Related
harness
B23 VIO Line Pressure Solenoid OutputLine pressure
solenoid Voltage
At D range
stall Less than 2V Solenoid
Page 4150 of 4264
7A2-158 DIAGNOSIS (JR405E)
No. Wire
Color Pin Name Input /
OutputConnected toMeasurement
Item Measurement
Condition StandardInspection
Point at
Trouble
At key switch
ON 10 – 14.5V Related
harness
B24 WHT V ign (Ignition Power Supply) Input Key switch Voltage
At Key switch
OFF Less than 2V Fuse
7.14ms 7.14ms
Time Time
0.714ms 6.426ms
Voltage
Off duty 10% =Throttle Position 0%
Voltage
Off duty 90% =Throttle Position 100%
Engine Speed Sensor Reference Wave Form
Measurement Terminal: A7 (+) B5 (-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: At engine speed 2000rpm
0V
Vehicle Speed Sensor Output Reference Wave Form
Measurement Terminal: A10 (+) B5 (-)
Measurement Scale: 5V/div 50ms/div
Measurement Condition: Vehicle speed 20km/h at L range
in 1st gear
0V
Turbine Sensor Reference Wave Form
Measurement Terminal: B3 (+) B5 (-)
Measurement Scale: 5V/div 500micro sec/div
Measurement Condition: Vehicle speed 20km/h at L range
in 1st gear
0V
Vehicle Speed Sensor Reference Wave Form
Measurement Terminal: B13 (+) B5 (-)
Measurement Scale: 5V/div 5ms/div
Measurement Condition: Vehicle speed 20km/h at L range
in 1st gear
0V
Page 4153 of 4264
ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20
Page 4157 of 4264
ON-VEHICLE SERVICE (JR405E) 7A3-5
THROTTLE POSITION SENSOR
1
P1010052
The throttle position sensor (1) is fitted on the throttle
valve body.
Adjust
1. Turn the starter switch to the “ON ” position.
2. Measure the voltage between TPS connecto
r
terminals (B) (output) and (A) (ground).
Note:
Do not remove the sensor connector.
Make sure that power source (5.0 0.01 V) is
measured between TPS connector terminals (C) and
(A) before measurement at step 2.
Standard voltage :
Throttle Angle TPS
Idling (0%) 0.2 - 0.3 V
WOT (100%) 3.4 – 4.1 V
RTW37ASH0013
3. If the reading is beyond the specified value, loosen
the throttle position sensor fixing bolts, and turn i
t
right or left, so that the specified output voltage be
obtained.
After adjusting, tighten the throttle position sensor
fixing screws (2).
826R300013
Page 4158 of 4264
7A3-6 ON-VEHICLE SERVICE (JR405E)
INHIBITOR SWITCH
The inhibitor switch is attached to the right side of the
transmission.
Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Disconnect the harness connectors.
4. Use a ohmmeter to check the inhibitor switch
continuity between the following terminals as shown
in figure.
5. Place the select lever in the “N” range.
249R300001
6. Move the select lever to either side.
Check the inhibitor switch continuity between the
terminals shown in Step (4).
The continuity readings should remain fairly steady
as the select lever is moved.
If there is no continuity or the continuity is
intermittent, the inhibitor switch must be adjusted.
Adjust
1. Disconnect the shift calbe from the lever.
2. Loosen the inhibitor switch bolts.
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
4. Tighten the 2 inhibitor switch bolts to the specified
touque.
Torque: 5.5 N·m (48 lb·in)
47INH-SW01
5. Connect the shift cable to the lever.
6. Connect the harness connector.
Remove or Disconnect
1. Remove the cable bracket (1) from the transmission.
2. Disconnect the shift cable (2) from the lever (3).
3. Disconnect the harness connectors.
4. Remove the inhibitor switch bolts.
5. Remove the inhibitor switch (4) from the
transmission.
238R300001
Page 4159 of 4264
ON-VEHICLE SERVICE (JR405E) 7A3-7
Install or Connect
1. Install the inhibitor switch (4) to the transmission.
Temporarily tighten the inhibitor switch bolts.
2. Move the manual shaft select lever to the “N” range.
249R300002
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
4. Tighten the 2 inhibitor switch bolts to the specified
torque.
Torque: 5.5 N·m (48 lb·in)
47INH-SW01
5. Install the cable bracket (1) to the transmission.
6. Connect the shift cable (2) to the lever (3).
7. Connect the harness connector.
8. Connect the negative battery cable.
9. Remove the wheel blocks.