fluid ISUZU TF SERIES 2004 Manual PDF

POWER-ASSISTED STEERING SYSTEM 3B-11

Power Steering Unit
Power Steering Unit and Associated Parts

This illustration is based on the RHD model. 431R300016
Legend
(1) Crossmember
(2) Power Steering Unit Assembly
(3) Bracket
(4) Universal joint (Steering shaft)


Removal
1. Remove the universal joint assembly.
Make a setting mark across the coupling flange and
steering unit to ensure reassembly of the parts in
the original position.
2. Drain power steering fluid.

3. Remove the tie rod end assembly from knuckle.
Use tie rod end remover 5-8840-2005-0.

3B-18 POWER-ASSISTED STEERING SYSTEM

Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaf
t
assembly to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the bolt, rear housing and O-ring.
5. Remove the snap ring.
6. Remove the shaft assembly.
7. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
8. Remove the pump cartridge assembly from the fron
t
housing.
9. Remove two O-rings.

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When par
t
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.



Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finge
r
nail.
The parts with minor scores may be reused after lapping
the face.

Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.

O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

POWER-ASSISTED STEERING SYSTEM 3B-19

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contac
t
with the inner wall of cam.
442RS005

4. Install roter and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N




m (2.2-2.7kg




m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 7.8-12 N




m (0.8-1.2kg




m/69-104 lb in)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N




m (5.0-7.0kg




m/36-51 lb ft)

Main Data and Specifications
General Specifications
Oil pump Type Vane
Operating fluid
ATF DEXRON®
III

3B-24 POWER-ASSISTED STEERING SYSTEM

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail. The parts with minor scores may be reused after
lapping the face.

Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Needle bearing fitting
face must be free from damage and wear.

O-ring, Oil Seal, Retaining Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N




m (2.2-2.7 kg




m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 7.8-12 N




m (0.8-1.2 kg




m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N




m (5.0-7.0 kg




m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N




m (1.5-2.0 kg




m/11-14 lb ft)

POWER-ASSISTED STEERING SYSTEM 3B-25

Main Data and Specifications
General Specifications
Oil pump Type Vane
Operating fluid
ATF DEXRON®
III



Torque Specifications
C24SE N
m (kg
m/Ib ft)


RTW43BLF000401

3B-28 POWER-ASSISTED STEERING SYSTEM

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When par
t
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finge
r
nail.
The parts with minor scores may be reused after lapping
the face.

Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.

O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connecto
r
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.

3B-30 POWER-ASSISTED STEERING SYSTEM

Main Data and Specifications
General Specifications
Oil pump Type Vane
Operating fluid
ATF DEXRON®
III



Torque Specifications
6VE1 N
m (kg
m/Ib ft)


RTW43BMF000401

TRANSFER CASE 7D-7

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1.
Disconnect battery ground cable.
2.
Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove the center exhaust pipe(5). (6VE1 only)
4.
Remove rear propeller shaft (1) and front propelle
r
shaft (2)(3).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
5.
Disconnect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
6.
Remove transfer case (4) from the vehicle.
Installation
1.
Apply a thin coat of molybdenum disulfide grease to
the input shaft spline as shown in the figure.

260R300001

7A2-44 TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)

Diagnostic Aids

Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring. Inspect
for a broken wire inside the insulation.

When diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
 Check oil temperature sensor for proper mounting
and adjustment.



DTC P0712 (FLASHING CODE 15) Transmission Oil Temperature Sensor
Circuit Low Input


Step Action Value(s) YES NO
1
Was the powertrain On-Board Diagnostic (OBD)
System Check performed? — Go to Step 2 Go to OBD
System Check
2 Perform the transmission fluid checking procedure.
Refer to checking Transmission Fluid level and
Condition in Automatic Transmission 7A section.
Was the fluid checking procedure performed ? — Go to Step 3 Refer to
Checking
Transmission
Fluid level and
Condition in
Automatic
Transmission
(AW30-40LE)
section
3

1. Install the scan tool.

2. Key “ON"
3. Review and record scan tool data.

4. Operate the vehicle with in scan tool data.
Does the scan tool indicate DTC P0712 ? — Go to Step 4 Refer to
Diagnostic Aids
4 Measure the voltage of the transmission fluid
temperature sensor by the J39200 DMM.

1. Key “OFF".
2. Disconnect the oil temperature sensor connector.

3. Key “ON".

4. Connect the J39200 DMM to the each terminal of
the oil temperature sensor connector E83-2 and
E83-1.
Does the scan tool indicate less than specified
value ? 5V Go to Step 5 Go to Step 6
5 Replace the transmission fluid temperature sensor.
Is the action complete ? — Verify repair —

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-47

Diagnostic Aids

Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring. Inspect
for a broken wire inside the insulation.

When diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.

Check oil temperature sensor for proper mounting
and adjustment.

DTC P0713 (FLASHING CODE 16) Transmission Oil Temperature Sensor
Circuit Hight Input


Step Action Value(s) YES NO
1
Was the powertrain On-Board Diagnostic (OBD)
System Check performed ? — Go to Step 2 Go to OBD
System check
2 Perform the transmission fluid checking procedure.
Refer to Checking Transmission Fluid Level and
condition Automatic Transmission7A section.
Was the fluid checking procedure performed ? — Go to Step 3 Refer to
checking
Transmission
Fluid Level and
Condition
Automatic
Transmission
(AW30-40LE)
section
3

1. Install the scan tool ?

2. Key “ON"
3. Review and record scan tool date.

4. Operate the vehicle with in scan tool data.
Does the scan tool indicator DTC P0713 ? — Go to Step 4 Go to
Diagnostic Aids
4 Observe the voltage of the transmission fluid
temperature sensor on the TECH2 data.

1. Key “OFF".

2. Disconnect the transmission fluid temperature
sensor connector E-83
3. Install a fused jumper wire from terminal E83-2 to
E83-1 on the mission harness.

4. Key “ON".
Does the scan tool indicate more than specified
value ? 0.4V Go to Step 5 Go to Step 6
5 Replace the transmission fluid temperature sensor .
If the action complete ? — Verify repair —