oil 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 3616 of 4264
7D-28 TRANSFER CASE
19. Align the shift shaft splines with the shift drum and
install the shafts to the drum.
RTW320MF000201
Legend
(1) H-L Sleeve and Shift ASM
(3) Shift Shaft
(2) 2-4 Sleeve ASM with Main Shaft and Shift ASM
(4) Shift Drum
NOTE: Be careful in the direction of an assembly.
P1010041/020124
20.
Coat the main shaft with oil.
21.
Align the block ring, the outside ring, and the inside
ring with the 2-4 hub assembly and install them.
22.
Assemble the sprocket, transfer chain, and front
output shaft.
23.
Install the sprocket, transfer chain, and front output
shaft to the main shaft and the transfer case.
Page 3617 of 4264
TRANSFER CASE 7D-29
24.
Align the sprocket thrust washer with the main shaft
groove and install it.
226R300009
25. Select a snap ring that will allow minimum axial play.
Insert it to the main shaft installation groove.
mm (in
)
Snap ring thickness
Identification color
2.15 (0.085)
Red
2.10 (0.083)
Not colored
2.05 (0.081)
Blue
2.00 (0.079)
White
226R300008
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) Sprocket
(5) Chain
(6) Front Output Shaft
(7) Thrust Washer
(8) Snap Ring
26.
Measure the snap ring external diameter. If the
measured diameter is outside the specified range, a
larger or smaller snap ring must be used.
Snap ring outside diameter (Standard):
53.0
0.5 mm
27.
Position the rear cover so that its mating surfaces
are facing up.
28.
Use a press and the installer (5-8840-2783-0) to
install the front output shaft needle bearing. The
installer must be aligned with the bearing
manufacturer's name (stamped into the bearing).
29.
Install the oil pump wire snap ring to the rear cover.
Page 3618 of 4264
7D-30 TRANSFER CASE
226R300005
30.
Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31.
Use a press and the installer (9-8522-1268-0) to
install the rear output shaft ball bearings. Do not
drive the ball bearings into place with a hammer.
32.
Install the rear output shaft retaining ring.
33.
Place the oil pump in its specified position.
34.
Secure the pump strainer to the rear cover and
tighten the bolts to the specified torque.
Rear cover and transfer case bolt torque:
15 Nm (1.5 kgm/11 lb ft)
226R300010
35.
Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
Legend
(1) Oil Pump ASM
(2) Wire Snapring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend
(1) Wire Snapring
Page 3619 of 4264
TRANSFER CASE 7D-31
226R300011
36.
Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 Nm (2.2 kgm/16 lbft)
37.
Apply engine oil to the companion flange O-ring.
38.
Install the O-ring to the front output shaft.
39.
Secure the front companion flange with the
companion flange holder (5-8840-0133-0).
40.
Install the end nuts and tighten them to the specified
torque.
Front companion flange end nut torque:
137 Nm (14 kgm/101 lbft)
41.
Use a cold chisel to caulk the front companion
flange end nuts.
226R300012
RUW34DSH000301
Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)
42.
Apply Loctite 575 to the threaded portion of the
detenteplugs.
Page 3620 of 4264
7D-32 TRANSFER CASE
43.
Use the installer (5-8840-2787-0) to install the main
shaft end snap ring to the rear output shaft (from the
back end of the shaft). Be absolutely sure that the
snap ring is seated in the groove.
226R300022
44.
Use the installer (5-8840-2786-0) to install the rea
r
output oil seal to the rear case.
45.
Install the detent balls, the detent springs, and the
detent plugs (2 parts each) to the transfer case.
Tighten the plugs to the specified torque.
Detent plug torque: 19 Nm (1.9 kgm/14 lbft)
46.
Install the neutral switch (black harness cover) to the
transfer case and tighten the bolts to the specified
torque.
Neutral start switch bolt torque:
39 Nm (4 kgm/29 lbft)
47.
Install the 2-4 switch (gray harness cover) to the
transfer case and tighten the bolts to the specified
torque.
2-4 switch bolt torque: 39 Nm (4 kgm/29 lbft)
48.
Install the switch bracket to the transfer case and
tighten the bolts to the specified torque.
Switch bracket bolt torque:
15 Nm (1.5 kgm/11 lbft)
49.
Install the transfer actuator assembly to the transfe
r
case and tighten the bolts to the specified torque.
The actuator must be installed in the same direction
as the shaft.
Transfer actuator assembly bolt torque:
22 Nm (2.2 kgm/16 lbft)
50.
Install the breather hose between the transfe
r
actuator and the transfer case.
51.
Install the speedometer driven gear, the
speedometer bush, and the speedometer stay to the
transfer case. Tighten the bolts to the specified
torque.
Speedometer bolt torque:
15 Nm (1.5 kgm/11 lbft)
52.
Install the drain plug to the transfer case and tighten
it to the specified torque.
Drain plug torque: 39 Nm (4 kgm/29 lbft)
53.
Loosen and remove the filler plug. Add the specified
volume of transfer oil (5W-30) or the equivalent to
the transfer through the filler hole.
Transfer oil volume: 1.3 liters
54.
Replace the filler plug and tighten it to the specified
torque.
Filler plug torque: 39 Nm (4 kgm/29 lbft)
55.
Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque: 39 Nm (4 kgm/29 lbft)
Page 3621 of 4264
TRANSFER CASE 7D-33
Main Data and Specifications
General Specifications
Type Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Planetary type gears shifting between “low" and “high".
Control method Remote control with the button switch on the instrument panel for gears
shifting among “2H" , “4H" and “4L".
Gear ratio High; 1.000
Low; 2.482
Oil capacity 1.3 lit. (1.37 U.S. quart)
Type of lubricant BESCO GEAR OIL TRANSAXLE (5W-30)
Refer to chart in Section 0
Torque Specifications
Nm (kgm/lb ft)
RTW47DLF000201
Page 3624 of 4264
7D-36 TRANSFER CASE
Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5-8840-2786
Transfer case oil seal
installer 5-8840-2784-0
Ring gear installer
5-8840-0084-0
Sliding hammer 5-8840-0133-0
Flange holder
5-8840-0027-0
Rear output shaft needle
bearing replacer 5-8840-2782-0
Needle bearing installer
5-8840-2293-0
Punch; end nut 5-8840-2783-0
Needle bearing installer
5-8840-2788-0
Front output shaft needle
bearing replacer 5-8840-0007-0
Driver handle
5-8840-2785-0
Input shaft and/or front
output shaft oil seal
installer 5-8840-1268-0
Rear output shaft ball
bearing installer
Page 3660 of 4264
7D1-34 TRANSFER CONTROL SYSTEM
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shft on the fly)
If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz and, at the
same time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes
out.
Cause of excessive synchronous shifting load
Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization)
High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and axle, connecting the front wheel
and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed
, the indicator flashes
at a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.
2.
When shifting from 4H to 2H
2-1 When 4WD indicator continues flashing at 2Hz
When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed. When torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.
: Shift on the fly only.
Page 3681 of 4264
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)
CONTENTS
Service Precaution .................................................
7A2-2
General Description ...............................................
7A2-2
Electronic Control Diagram ...............................
7A2-3
Transmission Control Module (TCM) (1/2) ......
7A2-4
Transmission Control Module (TCM) (2/2) ......
7A2-5
TCM Point Table .................................................
7A2-6
TCM Voltage & Resistance Check Sheet .......
7A2-7
Control System Diagram ....................................
7A2-9
Control and Functions ........................................
7A2-10
Gear Shift Control 3rd start ...............................
7A2-10
Mode Type ...........................................................
7A2-10
Mode Selection ....................................................
7A2-10
Comparison of mode ..........................................
7A2-11
3rd start Mode .....................................................
7A2-11
Backup Mode .......................................................
7A2-11
Functions of Input / Output Components ........
7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................
7A2-13
High speed CAN bus ..........................................
7A2-13
Diagnosis .................................................................
7A2-13
Electronic Diagnosis ...........................................
7A2-13
Check Trans Indicator ........................................
7A2-13
On Board Diagnostic Check ..............................
7A2-13
"Check Trans" Check .........................................
7A2-14
Tech 2 OBD Connection ....................................
7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............
7A2-30
16 - Terminal Data Link Connector (DLC) ......
7A2-31
Clear DTC ............................................................
7A2-32
DTC Check ..........................................................
7A2-32
TCM Precaution ..................................................
7A2-32
Information On TCM ...........................................
7A2-32
TCM Diagnostic Trouble Codes ........................
7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ...........................................
7A2-34
DTC P0602 (FLASHING CODE 63)
Transmission Control Module (TCM)
Programming Error ................................................
7A2-36
DTC P0705 (FLASHING CODE 17)
Transmission Range Sensor Circuit
Malfunction .............................................................
7A2-38
DTC P0712 (FLASHING CODE 15)
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................
7A2-42
DTC P0713 (FLASHING CODE 16)
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................
7A2-45
DTC P0717 (FLASHING CODE 14)
Input Speed Sensor Signal Error .........................
7A2-48
DTC P0722 (FLASHING CODE 11)
Output Speed Sensor Signal Error .....................
7A2-51
DTC P0743 (FLASHING CODE 33)
Torque Converter Clutch Electrical .....................
7A2-54
DTC P0748 (FLASHING CODE 35)
Pressure Control Solenoid Electrical ..................
7A2-57
DTC P0753 (FLASHING CODE 31)
Shift Solenoid S1 Electrical ..................................
7A2-60
DTC P0758 (FLASHING CODE 32)
Shift Solenoid S2 Electrical ..................................
7A2-63
DTC P1767 (FLASHING CODE 67)
ECM CAN Invalid ...................................................
7A2-66
DTC P1790 (FLASHING CODE 61)
Transmission Control Module ROM
Checksum Error .....................................................
7A2-69
DTC P1791 (FLASHING CODE 62)
Transmission Control Module RAM
Error .........................................................................
7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................
7A2-73
Page 3686 of 4264
7A2-6 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)
TCM Point Table
RTW37ASF000101-1
PIN No. SIGNAL NAME
A1 GND
A2 PRESSURE CONTROL SOLENOID GND
A3 —
A4 PRESSURE CONTROL SOLENOID
A5 L-up SOLENOID
A6 STARTER SW(IG1)
A7 CAN COMMUNICATION (-)
A8 —
A9 —
A10 —
A11 T/M OIL TEMPERATURE SENSOR
A12 T/M OIL TEMPERATURE SENSOR GND
A13 —
A14 —
A15 SHIFT SOLENOID (S2)
A16 SHIFT SOLENOID (S1)
A17 CAN COMMUNICATION (+)
A18 —
A19 —
A20 —
A21 —
A22 —
A23 GND
A24 BATTERY
PIN No. SIGNAL NAME
B1 NEUTRAL START SW (R)
B2 POWER LAMP
B3 CHECK TRANS LAMP
B4 PATTERN SELECT SW (3rd START)
B5 SPEED SENSOR (+)
B6 INPUT REVOLUTION SENSOR (+)
B7 NEUTRAL START SW (D)
B8 NEUTRAL START SW (N)
B9 NEUTRAL START SW (3)
B10 3rd START LAMP
B11 OIL TEMPERATURE WARNING LAMP
B12 DIAGNOSIS TERMINAL
B13 PATTERN SELECT SW (POWER)
B14 SPEED SENSOR (-)
B15 —
B16 INPUT REVOLUTION SENSOR (+)
B17 —
B18 NEUTRAL START SW (L)
B19 NEUTRAL START SW (2)
B20 NEUTRAL START SW (P)
B21 TRANSMISFER LOW 4 SW
B22 BRAKE LAMP SW
B23 DIAGNOSIS OUT PUT
B24 —
B25 —
B26 CRUISE CONTROL UNIT