transmission ISUZU TROOPER 1995 Owners Manual

7A-16 AUTOMATIC TRANSMISSION (4L30-E)
DRIVER INFORMATION
To analyze the problem fill a complete description of the owner's complaint.
Please draw a circle around the right information and complete the following form. (Find next page an
example of form completed). You can draw a circle around many numbers if you are not sure.
A-Today' a date : Month: ............... Day:·············· Year: ...............
B-Ead User Name, Address :
C-Dat~ of Problem : Month: ..................... Day: ................. Year: ................
D-Mileaae: E-With Ignirioa. ON ia OIECK F -Car load wheo proHem oceand :
...............
Miles/Km TRANS lodicator : 1 - Towing a trailer 2-.......... people OR ......... Kg
1-Flashing 2-Not Flashing
G-Weather coa.ditiou whea. H-Weather Temperature whea I -Road Cooditioaa wheu problem J-Frequeucy ofthe Problem :
!Problem: problem: : 1-Always 2-Occuional :
1-Clear 2-Cloudy 1-Hot 2-Warm 1-Any 2-Inter City ........ times/day,
3-
Rain 4-Snow 3-Cool 4-Cold 3-Outsid~ City 4- Highway douooo times/month
5- Unstable
6-Any 5-Unstable 6- Any S-Uphill 6-Downhill 3-
Only Once 4-Otheu:
7-Unpaved 8-Snow
9-Others:
IK-EJI&iae Coaditioa : L-Eagiae Spttd whca the problem M-Traasmissiou Coa.diriou wbea
1-Always 2- At Cold occand: it occund:
3-During Warming up 1-Idling 2-Starting 1-Any 2-
Idling
4-After Warming or Hot 3-Stalling 4-HighRPM 3-Starting 4-Driving
5-Others 5-LowRPM 5-Accelerating 6-Coasting
7-Inc:omer 8-Shifting
N-If then b a Trauamiuioa drivcabillty problem BEFORE TIIE CHECK TRANS
INDICATOR WAS FI..ASHING :
I-No Power in Range: All-P-R-N-D-3 -1-L during
a : upshift : 1-2 I 2-3 I 3~4 or downshift : 4-3 I 3-2 I 2-1
2-No shift in Range :All-P-R-N-D-3-2-L during a: upshift
: 1-2 I 2-3 I 3-4 or downshit : 4-3 I 3-2 I 2-1
3- Shift Shock in Range: All-P-R-N-D -3-2-L during a
:upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
4-Shift Slip in Range: Ali-P-R-N -D-3 -2 -L during a: upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
5-Shift Delayed in Range : All -P -R-N - D - 3 - 2 - L during a: upshift :
1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
6-Shi1 Point too high in Range :All -P-R-N-D-3-2. L during a: upshift:
1-2 I 2-3 I 3-4 or downshift: 4-3 I 3-2 I 2-1
7-Shift Point too low
in Range : All -P -R-N-D-3 -2-L during
a : upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
S-TCC Shudder in Range :All-P-R. N-D-3-2-L during a: upshift
: 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
9-Noise in Range : All -P -R-N - D - 3 - 2 - L during a: upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
INolae type: 1-Buzz 2-Whine 3-Clunk 4-Rattle S-Whistle II 6-light 7-medium 8-hoavy
10-Other: ..................... in Range : All -P -R-N - D - 3 - 2 - L during a: upshit :
1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
0-Other cDitomer co aura. aad commeats
P •
bUZD Vebiele Code : ooo,0ooooooooooou• .. ouooooooooooooo•••••o•U Q-VIN Number ··················\
··················\
··········
R-Date orVebiclc Regjatratiou Month: ..................... Day: .............. Year: ...............
S • Traua. model: .................... -. ......................... T-Aff Serial Number : uo••••••••••••••••••\
•••oo•oooooooooooooouooo
U-Your aame: ··················\
··················\
··········
y. Dealer Naau, Addn .. , Pbou~
•

AUTOMATIC TRANSMISSION (4L30-E) 7A-17
Example of form completed.
A-Today's date : Month : April .............. Day: .13 ............. YOM: .1994 ..............
B-Ead U.er Name, Address : Dave Smith
6584, Arlington road
P1ymoutll Ml 48170
USA
C-Date or Problem :
Month : April... ................ Day:.8 ................ You : .1994 ...............
D-Mileace: E-With lguirioa ON is CHECK F -Car load whcu problem occartd:
12230 .. J.@1Km @! TRANS ludicator: 1 -Towing a trailer 2-.. 2 ....... people OR ......... Kg ashing 2-
Not Flashing
G-Weatbtr couditious wbeu H-Weather Temperature wheu I-Road Conditions ""hen problem J-Frequency or the Problem : problem: problem: : 1-Always ~sionaJ :
1-Clear 2- Cloudy 1-Hot 2-Wann 1-Any l.-lltto:r City ........ fio•~s/ y,
3-
Rain 4-Snow 3-Cool ~d 3-Owside City (j}Highway .. .3 ... tim~stmonth 5-Unstable (!).ny S-Unstable 6- y 5-Uphill ti-Downhill 3-Only Once 4-Otb.n: 7-Unpaved )8t.now 9-Others .......___
l!Jis 111P.
K -Euciue Coa.dition : L-Engiue Speed wbea the problem M-Traasmiuioo Condition wheu ~e IJJis 7~~· do l1ot
!-Always 2-At Cold occared: it occared: lJto a
~ing Warming up 1-Idling 2-Starting 1-Any 2-Idling C'collnt
er Warming
or Hot 3-Stalling (3Higt~RPM 3-Starting 4-Driving
5-Others S-Low RPM (~cceleratin~~~~g 7-lr. comer 8-JUftmg
IN-Irtbcrt is a Transmission drive ability problem BEFORE THE CHECK TRANS INVJCATOR WAS FLASHING :
1-NoPower in Range : All -P -R-N-D-3 - 2 - L during a: upshift: 1-2 I 2-3 J 3-4 or downshift: 4-3 I 3-2 / 2-1
~hift inR.ange:AII-P-R-~-0-3-2-L during a : up~hifl : 1-2 I 2-3 ! 3-4 01 uowushifl : ~-3 I 3-2 I 2-1 Shock in Range: AII-P-R-N -~ -2-L during·~-: I 2-3 I (Do~:Qi 3-2 I 2-l 4-Shift Slip in Range : All -P -R-N - D - 3 - 2 - L during a: ups "ft : 1-2 I 2-3 / 3-4 or dov.nshift : 4-3 / 3-2 I 2-1
S-Shift Delayed
in Range,.: All -P -R-N -D-3 -2 - L during
a :upshift : 1-2 I 2-3 I 3-4 or dovmshift : 4-3 I 3-2 I 2-1
6-Shift Point too higJl in Range :All -P-R-N • D-3-2-J.. during a : upshift : 1-2 I 2-3 ! 3-4 or downshift : 4-3 I 3-2 I 2-1 7-Shift Point too low
in Range :All -P-R-N-D-3-2; L during a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
8-TCC Shudder
in Range : All -P - R
- N - D - 3 -2 - L during
a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
9-Noise in Range : All -P -R-N -D-3 -2-L during a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
~oise type: 1-Buzz 2-Whine 3-Clunk 4-lWtle S-Whistle II 6-light 7-medium 8-heavy
10-0thor: ..................... inR.ange:AII-P-R-N-0-3-2-L during
a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
0-Other customer co accra aa.d com meat• :
(This is just an e~ample ). Shift shock very harsh
overall during a downshift. Not sure if
it's the 4-3 or 3-2.
P-huza Vehicle Code : 94 UCR Q -VIN Number 4S2CV58ZXM432404 7
R-Date ofVehieJe Re~stratioa Month : .November. Day: ... .18 ........ Year: . .1993 .........
S -Traaa.. mtldel : 4L30-E T-Aff Serial Number : 96 358 654
U-Yoali'D.ame: Joe Spring
V-Dealer Name, Address, Phooe
Kent Helfrich
Home-town ISUZU
900 -999 -9999

7A-18 AUTOMATIC TRANSMISSION (4L30-E)
GENERAL DIAGNOSIS PROCEDURE
I Complaint
1 Follow PRELIMINARY
INSPECTION CHART
Remove transmission
assembly and
repair/replace
as
required
transmission assembly
NO
NO
Perform repair
per
SYMPTOMS CHART
Can fault
TEST DRIVING
YES
YES
•

AUTOMATIC TRANSMISSION (4l30-E) 7A-19
PRELIMINARY INSPECTION CHART
Does symptom reflect
NORMAL OPERATIONS
OF 1994 -95 4L30·E
TRANSMISSION?
(See p.age-1-Ac13)
YES
Check CHART3: TRANSMISSION AND TCM IDENTIFICATION on page-~n.
Check TRANSMISSION FLUID LEVEL and CONDITION. See--page"'7A'•2'0.
Check manual linkage. TCM:
Transmission Control Module
Hydraulic system appears OK!
Are any DTC's stored in TCM?
NO
Refer to MANUAL LINKAGE in this manual.
See~.
Ll_v_e_rify_e_n_g_in_e..:.p_e~rf_or_m_a_n_c_e. ___ l--------1•~1 Refer to Engine Seeticm.
Road
test vehicle to verify concern l----------;..f~s~e;;e-;:ga;;;:;:ge~7.A:o.~2i2f;fo;;r~TiE:SsTTDD~RmlvliiNNiGG~.l
UCHECK TRANS"
flashing >--Y-ES ________ ~ See CHECK TRANS INDICATOR
CHART
on page 7A-23.
Any
Trouble Codes stored by TCM?
YES
See
MECHANICAL/HYDRAULIC DIAGNOSIS.~.
See ELECTRONIC DIAGNOSIS. ~r tliis nusnllal on-JH!ge 7A 45.

7 A-20 AUTOMATIC TRANSMISSION (4L30-E)
CHECKING TRANSMISSION FLUID
LEVEL AND CONDITION
Checking fluid level and condition (color and odor)
at
regular intervals will provide early diagnosis
information about the transmission. This inform­
ation may be used to correct a condition that, if not
detected early, could result in major transmission
repairs.
IMPORTANT: When new, automatic transmission
fluid is red in color. As the vehicle is driven, the
transmission
fluid will begin to look darker in color.
The
color may eventually appear light brown.
A DARK
brown color with burnt odor may indicate
excessive
fluid deterioration and signal a need for
fluid change.
FLUID LEVEL
When adding
or changing fluid, use only DEXRON
®-Ill.
Refer to the Maintenance and Lubrication (Section 0
of this manual) for maintenance information and
servicing
interval.
\f CAUTION: DO NOT OVERFILL
Overfilling will cause foaming, loss ~f fluid,
abnormal shifting and possible damage to
the transmission.
1. Start engine and drive vehicle until normal AfT
oil operating temperature is reached:
NOTE: The automatic transmission fluid level
must be checked with the vehicle at normal
A/T oil operating temperature: 75 TO 85°C
(167 TO 185°F) MEASURED WITH TECH1 SCAN
TOOL.
Temperature will greatly affect transmission
fluid level.
If the vehicle is not at normal AfT oil operating
temperature and the proper checking
procedures are
not followed, the result could
be a false reading of the fluid level indicator
and
an incorrect adjustment of the fluid level.
2. Park vehicle on level ground.
3. Move gear selector to "Park".
4. Apply parking brake and block wheels.
5. Allow vehicle to idle for 3 minutes with all
accessories turned off.
6. Check fluid level with engine running at idle:
Fluid should
be in "HOT" area on AfT dipstick
(Fig. 7A-6).
Check also color and condition (Refer to next
page.)
Hot
Cold ---IIU 0
0
Min
Dipstick
Fig. 7A-6
\f CAUTION:
DO NOT CHECK FLUID LEVEL UNDER THESE
CONDITIONS: •
At high ambient temperature above 30°C
(86°F).
Immediately after driving at sustained highway
speeds.
• In heavy city traffic during hot weather.
If vehicle is towing a trailer.
If the vehicle has been operated under these
conditions,
shut the engine off and allow the
vehicle to "cool" for thirty (30) minutes. After the
cool-down period, restart the vehicle and continue
from step 2 above.
'~I
......

AUTOMATIC TRANSMISSION (4L30-E) 7A-21
FLUID CONDITION
FLUID CONDITION
NORMAL* CONTAMINATED
COLOR
RED BROWN NON-TRANSPARENT BROWN OR LIGHT BROWN
/PINK
DRAIN NO
YES YES YES
REQUIRED?
CO NT AMI- NONE Very small amount Contamination by Large pieces of
NATION of foreign material coolant or other metal or other
in bottom of pan
source foreign material in
bottom of pan
1. LOW LEVEL:
A. Add fluid to -
Remove both pans -Repair/replace
obtain
proper radiator cooler
level
& check -Change filter -Transmission -Transmission
CORRECT for external overhaul required overhaul required
LEVEL leaks. See -Flush cooler -Check for:
& chart 16..811 • Damaged plates -Flush cooler and
CONDITION ~· -Add new fluid and seals cooler
lines
B. Correct cause • Contaminated -Add new fluid
of leak. -Check level solenoids
2. HIGH LEVEL: -Flush cooler -Check level
-Remove excess -Add new fluid
fluid -Check level
* Fluid should be changed according to maintenance schedule.

7 A-22 AUTOMATIC TRANSMISSION (4l30-E)
TEST DRIVING
Some 4L30-E automatic transmission complaints
vehicles will require a test drive as a part of the
diagnostic procedure.
Some codes will not set
unless the vehicle is moving. The purpose of the
test
drive is to duplicate the customer's complaint
condition and set a current Transmission Control
Module (TCM) trouble code. Perform this
procedure before each 4L30-E automatic trans­
mission repair, and again after repairs are made.
IMPORTANT:
• Duplicate the condition under which the
customer's complaint was observed.
• Depending on the complaint, line pressure
gauge and the
TECH1 scan tool may be
required
during the test drive.
• During the test drive, it is important to record
all necessary data from the areas being
monitored, for use in diagnosis. Also listen for
and note any unusual noises.
The
following procedure should be used to test
drive 4L30-E automatic
transmission complaint
vehicles:
1. Turn the ignition ON without starting the
engine. Check
that the "CHECK TRANS" lamp
comes on for approximately 2 to 3 seconds
and then goes
out and remains out.
• If the lamp is flashing, GOTO CHECK
TRANS INDICATOR (on page 7A-46).
• If no serial data is present, see Chart 1:
DIAGNOSTIC CONNECTOR AND VOLTAGE
SUPPLY TEST (on page 7A-69 and 7A-70).
• If the lamp stays ON or stays OFF, GOTO
"CHECK TRANS"
CHECK (on page 7A-48).
NOTE:
Remember that, when TECH1 is connected,
line pressure will be at maximum during shifts.
2. Drive the vehicle. During the test drive be sure
that the transmission achieves normal
operating temperature (approx. 20 minutes) ..
Allow the transmission to go through all of 1ts
gear ranges, checking shift timing and
firmness.
Duplicate the owner's complaint
condition as closely as possible during the test
drive.
3. If, during the test drive, the "CHECK TRANS"
lamp comes on, use the TECH1 to check for
trouble codes.
4. If, during the test drive, a problem is felt, but
the "CHECK TRANS" lamp does not come on
and
no trouble codes are present, drive the
vehicle with the TCM disconnected (manually
shifting the vehicle).
•
In Manual L, the vehicle operates in first
gear.
• In Manual 2, the vehicle operates in third
gear.
• In Manual 3 or "D", the vehicle operates in
fourth gear.
If the problem still exists with the TCM
disconnected, refer
to the MECHANICAL/
HYDRAULIC DIAGNOSIS
in this Section.
5. If no problem has been found at this point,
check
all underhood connections that supply
power to the TCM and ignition fuses.
Physically and visually inspect all the TCM
harness connectors
for loose or corroded
terminals. Inspect the TCM ground points.
•

MECHANICAL/HYDRAULIC DIAGNOSIS
CHECK TRANS INDICATOR CHART
AUTOMATIC TRANSMISSION (4L30-E) 7 A-23
I PERFORM PRELIMINARY INSPECTION FIRST!
When the "CHECK TRANS" indicator is flashing, it
indicates that a problem related to the trans­
mission, the Transmission Control
Module (TCM),
or the vehicle harness has occurred:
The system is
now operating in a "BACKUP MODE"
where the risk of further damaging the transmission
has been reduced. The vehicle may be shifted
manually.
If the initial problem is intermittent or seldom,
switching OFF/ON the engine might allow normal
operation again until the problem re-occurs.
I "CHECK TRANS" indicator flashing
I NO DTC I
I
Use "CHECK TRANS" CHECK in
Electronic Diagnosis section in this
manual
BACKUP MODE PATTERN:
-No automatic shifting
- Manual shifting only
-"CHECK TRANS" Flashing
Read and record the Diagnostic
Trouble Codes {DTCI stored by TCM.
WARNING: Disconnecting battery or TCM will result in loss of stored trouble code{s).
I ANY DTC J
I
Refer to appropriate DTC chart in
Electronic Diagnosis sectien in this
l'lUl,IUiah~ c " • •• "
SHIFT LEVER GEAR
POSITION p
R
N
D
3
2
L
SELECTED p
R
N
4
4
3
1

7 A-24 AUTOMATIC TRANSMISSION (4l30-E)
MECHANICAL/HYDRAULIC DIAGNOSIS SYMPTOMS INDEX
rr PERFORM PRELIMINARY INSPECTION FIRST! , -
CHART SYMPTOMS PAGE
1
NO ENGINE START IN NEUTRAL OR PARK 7A-25
2
NO FORWARD GEARS IN ANY RANGE/NO REVERSE 7A-26
3
NO ENGINE BRAKE IN ANY RANGE 7A-27
4
POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT) 7A-28
Sa DELAYS IN DRIVE AND REVERSE 7A-29
5b DELAYS
IN REVERSE ONLY
6 DIAGNOSTIC TROUBLE CODE (DTC) 61 7A-30
7 HARSH 1-2
SHIFT 7A-31
8 HARSH 3-4
SHIFT
9a 3-2 DOWNSHIFT
COMPLAINT
9b HARSH SHIFT WHEN SHIFTING INTO "D" OR ACCELERATING 7A-32 FROM STOP
9c COASTDOWN HARSH SHIFT OR CLUNK AT 3-2 DOWNSHIFT
10 INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED 7A-33
11 ENGINE FLARE AT SHIFTING
DURING TURNING ONLY 7A-34
12 ENGINE FLARE DURING 1-2 OR 2-3 SHIFT
13 SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING 7A-35
14
POSSIBLE CAUSES OF TRANSMISSION NOISE 7A-36
15a
POSSIBLE CAUSES OF LOW LINE PRESSURE 7A-37
15b
POSSIBLE CAUSES OF HIGH LINE PRESSURE 7A-38
16
POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS It 7A-39
= -NOTE:
Numbers with parenthesis on the following charts refer to Parts List at end of this ~n.
•

AUTOMATIC TRANSMISSION (4L30-E) 7 A-25
CHART 1: NO ENGINE START IN NEUTRAL OR PARK
PERFORM PRELIMINARY INSPECTION FIRST!
NO ENGINE START IN NEUTRAL
When shift lever moved from drive to neutral mostly in hot condition
Does
engine
also not start in neutral when
shift lever moved from
park to neutral?
NO
Open
in neutral
start circuit of mode
switch (63)
Replace mode switch (63)
( ) Refer
to Parts List at the end of this Section.
YES
NO START IN P
(Any condition)
Check mode
switch
(63) setting.
Readjust
if necessary. Problems fixed?
(~e 7 A-'Hi'1':')
NO
YES ~ ~----l~~