oil level ISUZU TF SERIES 2004 Repair 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 3980 of 4264
7A1-34 CONSTRUCTION AND FUNCTION
MAJOR INPUT/OUTPUT COMPONENT AND THEIR FUNCTIONS
Speed sensor Detects output shaft revolution and sends rpm signal to TCM.
Turbine sensor Detects input shaft revolution and sends rpm signal to TCM.
Engine speed sensor Inputs engine revolution from engine control computer.
Brake switch Detects brake pedal operated by the driver and sends signal to
TCM.
Inhibitor switch Detects select lever position and sends signal to TCM.
Mode select switch Detects "Power Drive" or "3rd Start" selected by the driver and
sends signal to TCM.
4L switch (4WD Only) Inputs 4L mode from transfer control computer.
ATF thermo sensor Detects ATF temperature and sends signal to TCM.
High clutch oil pressure switch Detects high clutch supply oil pressure and sends signal to
TCM.
2-4 brake oil pressure switch Detects 2-4 brake supply oil pressure and sends signal to
TCM.
Low & Reverse brake oil pressure switch Detects low & reverse brake supply oil pressure and signal to
TCM.
Throttle position sensor Inputs throttle opening angle from engine control computer.
Input
TCM Judges necessary line pressure, gear shifting point and lock-up
operation based on electrical signals from switches and
sensors and sends appropriate signals to solenoids.
Line pressure solenoid Regulates oil pump delivery pressure to the appropriate line
pressure for current driving condition based on signal from
TCM.
Low clutch solenoid Selects appropriate gear shifting position for current driving
condition and regulates low clutch supply oil pressure based on
signal from TCM.
High clutch solenoid Selects appropriate gear shifting position for current driving
condition and regulates high clutch supply oil pressure based
on signal from TCM.
2-4 brake solenoid Selects appropriate gear shifting position for current driving
condition and regulates 2-4 brake supply oil pressure based on
signal from TCM.
Low & Reverse brake solenoid Selects appropriate gear shifting position for current driving
condition and regulates low & reverse brake supply oil
pressure based on signal from TCM.
Lock-up solenoid Regulates lock-up pressure to appropriate level for current
driving conditions based on signal from TCM.
Mode indicator lamp Indicates POWER DRIVE or 3rd START switch position.
Speed meter signal (2WD Only) Outputs vehicle speed to speed meter.
A/T OIL TEMP indicator lamp Indicates A/T OIL TEMP indicator lamp in case of high
temperature.
Output
CHECK TRANS indicator lamp Indicates CHECK TRANS indicator lamp in case of
malfunction.
Page 4085 of 4264
DIAGNOSIS (JR405E) 7A2-93
No. A1: Vehicle Does Not Run in D, 3, 2, L and R Range
Description:
Vehicle does not run though the accelerator pedal is stepped on.
Diagnosis Hints:
Some trouble in the AT main unit is supposed (since the vehicle can run even if the TCM is defective). However,
since the trouble of the main unit may be originated from the sensor system or output system, these systems
should be also checked to prevent reproduce of the trouble.
Possible Cause:
Slip of clutch (low clutch, low one-way clutch, reverse clutch, low & reverse brake).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Shortage or faulty quality of ATF.
Dropped line pressure.
Trouble in control valve body (faulty operation, sticking, clogged oil passage).
Disordered select cable (select indicator light indicates D, 3, 2, L or R but the hydraulic system is not in the D, 3,
2, L, or R range).
Faulty torque generated.
Trouble in the torque converter (faulty operation, sticking), insufficient engine output.
Malfunction of parking mechanism.
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a
position other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select cable.
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is low,
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
4 Is the stall revolution correct in all range? Refer the STALL
TEST section in this manual.
Go to Step 5
Repair the defect or
replace.
5 Is the line pressure correct? Refer the LINE PRESSURE
TEST section in this manual. Trouble in the AT
assembly or control
valve.
Repair the defect or
replace.
Page 4086 of 4264
7A2-94 DIAGNOSIS (JR405E)
No. A2: Vehicle Does Not Run in R Range
Description:
Vehicle does not run in R range only.
It runs correctly in D, 3, 2, and L ranges.
Diagnosis Hints:
Some trouble in the AT main unit is supposed (since the vehicle can run even if the TCM is defective). However,
since the trouble of the main unit may be originated from the sensor system or output system, these systems
should be also checked to prevent reproduce of the trouble.
Possible Cause:
Slip of clutch (reverse clutch, low & reverse brake).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Shortage or faulty quality of ATF.
Dropped line pressure.
Trouble in control valve body (faulty operation, sticking, clogged oil passage).
Disordered select cable (select indicator light indicates R but the hydraulic system is not in the R range).
Faulty torque generated.
Trouble in the torque converter (faulty operation, sticking), insufficient engine output.
Malfunction of parking mechanism.
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a
position other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select cable.
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is low,
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
4 Is the stall revolution correct in R range? Refer the STALL
TEST section in this manual.
Go to Step 5
Repair the defect or
replace.
5 Is the line pressure correct? Refer the LINE PRESSURE
TEST section in this manual. Trouble in the AT
assembly or control
valve.
Repair the defect or
replace.
Page 4087 of 4264
DIAGNOSIS (JR405E) 7A2-95
No. A3: Vehicle Does Not Run in D, 3, 2 and L Range
Description:
Vehicle does not run in D, 3, 2 and L range only.
It runs correctly in R ranges.
Diagnosis Hints:
Some trouble in the AT main unit is supposed (since the vehicle can run even if the TCM is defective). However,
since the trouble of the main unit may be originated from the sensor system or output system, these systems
should be also checked to prevent reproduce of the trouble.
Possible Cause:
Slip of clutch (low clutch and low one-way clutch).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Shortage or faulty quality of ATF.
Dropped line pressure.
Trouble in control valve body (faulty operation, sticking, clogged oil passage).
Disordered select cable (select indicator light indicates D, 3, 2 and L but the hydraulic system is not in the D, 3, 2
and L range).
Faulty torque generated.
Trouble in the torque converter (faulty operation, sticking), insufficient engine output.
Malfunction of parking mechanism.
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a
position other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select cable.
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is low,
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
4 Is the stall revolution correct in D, 3, 2 and L range? Refer
the STALL TEST section in this manual.
Go to Step 5
Repair the defect or
replace.
5 Is the line pressure correct? Refer the LINE PRESSURE
TEST section in this manual. Trouble in the AT
assembly or control
valve.
Repair the defect or
replace.
Page 4088 of 4264
7A2-96 DIAGNOSIS (JR405E)
No. B1: Vehicle Runs in N Range
Description:
Creep appears in N range.
Vehicle moves unless the brake pedal is stepped on in N range.
Diagnosis Hints:
Basically a trouble in the AT main unit. However, some trouble in the sensor system or output system may have
some influence on the trouble in the main unit and therefore these systems should be also checked to prevent
reproduce of the trouble.
Possible Cause:
Seized clutch (low clutch, low one-way clutch, reverse clutch, low & reverse brake).
Trouble in the control valve (faulty operation, sticking, clogged oil passage).
Dislocated select lever (the select indicator light indicates the N range but the hydraulic system is in the D, 3, 2
or L range).
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a
position other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select cable.
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is low,
replenish up to the
specified level.
Trouble in the AT
assembly or control
valve.
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
Page 4096 of 4264
7A2-104 DIAGNOSIS (JR405E)
No. B5: Engine Stalls When Selecting From N Range to
R, D, 3, 2 or L Range
Description:
The engine stalls when selecting from N or P range to a run range during the engine idling.
Diagnosis Hints:
As causes attributable to the engine, faulty idle up, insufficient engine output, etc. are considered.
As a cause of the AT system, faulty lockup piston system (lockup engine stall) is considered.
If the oil through resistance increases remarkably due to clogged oil cooler or some other reason, or if the ATF
level decreases, the lock-up piston works causing the engine stall.
Possible Cause:
Disordered idling speed, faulty idle up, faulty engine output, shortage output.
Insufficient ATF quantity (dropped level).
Clogged oil cooler (foreign substance mixed in).
Faulty lock-up piston (clogged oil passage of solenoid drive circuit, faulty operation).
Step Action Yes No
1 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 2 Go to Step 2
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.
4 Check of engine idle up speed
Does the idle speed increase when the air conditioning or other
electric load is turned on?
Go to Step 5
Repair the defect or
replace.
Page 4108 of 4264
7A2-116 DIAGNOSIS (JR405E)
When signal from the speed sensor becomes out of order, it may be judged a result of changed vehicle
speed and faulty gear shifting may be the causes.
Trouble in control valve body (faulty operation, sticking, clogged oil passage)
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a position
other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select
cable.
2 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 3 Go to Step 3
3 Are any DTCs stored?
Go to DTC Chart Go to Step 4
4 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.
Go to Step 5
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Page 4113 of 4264
DIAGNOSIS (JR405E) 7A2-121
No. E1: No Gear Shift
Description:
Range is fixed without shifting the gear of 1st to 2nd, 2nd to 3rd, and 3rd to 4th.
Gear may be shifted or may not be shifted.
Diagnosis Hints:
Fixing at some gear speed, signal error from throttle position sensor or trouble in the AT main unit are supposed.
Possible Cause:
Slip of clutch (low clutch, high clutch and 2-4 brake).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Dropped line pressure.
Fixing at 3rd position (fail-safe activated).
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "No gear shift"
is resulted. In this case, the DTC is memorized.
When TCM stops operation because of faulty TCM ground, the gear is fixed at the 3rd position because
of a mechanical reason. In this case, no DTC is memorized.
Incorrect properties of throttle opening signal (serial communication) of throttle position sensor.
Throttle opening signal (serial communication) of the throttle position sensor does not change in
proportion to the throttle opening. In this case, fixing at the high or low gear results in such a trouble
that "No Gear Shift".
Trouble in control valve body (faulty operation, sticking, clogged oil passage)
Step Action Yes No
1 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out).
Go to Step 2 Go to Step 2
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.
Page 4116 of 4264
7A2-124 DIAGNOSIS (JR405E)
No. E2: Only 4th gear (O/D) is Not Selectable
Description:
Gear is not shifted up from 3rd to 4th though the vehicle is accelerated.
Possible Cause:
Disordered select cable.
Disordered inhibitor switch.
ATF thermo sensor detects low oil temperature (4th gear is prohibited temperature less than 10C.).
Clogged oil passage of low clutch duty solenoid.
Trouble in control valve body (faulty operation, sticking, clogged oil passage).
Step Action Yes No
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a position
other than the P range and the vehicle is pushed?
Go to Step 2
Adjust the select
cable.
2 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 3 Go to Step 3
3 Are any DTCs stored?
Go to DTC Chart Go to Step 4
4 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.
Go to Step 5
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.
Page 4124 of 4264
7A2-132 DIAGNOSIS (JR405E)
No. G3: Creep Force is small
Description:
Vehicle does not move though a run range is selected on a flat road during the idling.
Diagnosis Hints:
When the creep force is small in all ranges, low engine output is considered. Another possible cause is slip of
clutch. If the creep is normal only in the R range, operation of the fail-safe function due to a trouble in the electrical
system is considered.
Possible Cause:
Slip of clutch (low clutch).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Low engine output (low idling speed, out of injection timing, lowered compression pressure, etc.).
Shortage or faulty quality of ATF.
Disconnection or short circuit of solenoid valve output.
Clogged oil passage of solenoid valve output.
Faulty ground return line in AT assembly.
If the ground return line earth is faulty, clutch pressure may decrease causing slip of the clutch.
Trouble in the torque converter system (faulty operation).
Step Action Yes No
1 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or
more in each range: Start in the L range (1st) to 2 range
(2nd) to 3 range (3rd) to D range (4th) (to detect the gear
ratio trouble exactly, this process should be carried out)
Go to Step 2 Go to Step 2
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal? If the ATF level is low,
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
4 Are the idling speed and other engine system normal?
Go to Step 5
Repair the defect or
replace.
5 Is the stall revolution normal in D, 3, 2 and L range? Refer
the STALL TEST section in this manual.
Go to Step 6
Repair the defect or
replace.
6 Is the line pressure normal? Refer the LINE PRESSURE
TEST section in this manual. Trouble in the AT
assembly or control
valve.
Repair the defect or
replace.