check oil ISUZU TROOPER 1995 Workshop Manual

7A-140 AUTOMATIC TRANSMISSION (4L30-E)
WITHOUT DTC SET
1. If you have already checked the Diagnostic
Trouble Code (DTC) and the scan tool TECH1
does not provide any DTC, and you have
reproduced the
problem and no DTC was
stored:
This means that you have
to check the problem
by comparing the way it should work to the
way it works now that the problem exits.
2. To find the problem, perform the following
tests:
• A/TOil Temperature Indicator Test
• Transmission Operating Mode Test
•

AUTOMATIC TRANSMISSION (4L30-E) 7A-141
A/T OIL TEMPERATURE INDICATOR TEST
1. Working normally if it is ON for 2 to 3 seconds
with ignition switch ON (or when the engine is
cranked)
but it is OFF after.
2. Not working normally if it stays ON always
when ignition is ON.
CD This means that connection between the
Lamp and the Transmission
Control
Module (TCM) is shorted to ground.
r~,··mm -,-,~
• , I
I
TRANSMISSION
CONTROL
MODULE (TCM)
@ Verify if Indicator connector 1-1 terminal 2 is
shorted
to ground.
@ Verify if the TCM connector C-90 terminal
A10 is shorted to ground.
@ Verify that the Indicator connector 1-1
terminal 6 is connected to Battery.
@ If problem not solved GOTO TCM MEM­
CAL REPLACEMENT.
@ If problem solved see CHECK TRANS
INDICATOR
(page 7A-46).
AfT OIL TEMPERATURE INDICATOR ~-~--~I
C-90 ORNJBLU H-9 1~1 :·' ,.· . 'I 1-1 >-A-10--=.:..;.;_;:,=-~>>----<( · , . ' >• • _;__I ;:. 16 2 1 . • .i· ,..:., • 6
I ·•'I• ·. . , . . J
BLU!YEL
BLKJORND
BLK/IILU ~~
I II 1
I I
1_:1;_-:....... _]
WARNING BOX
FUSE BOX

7A-146 AUTOMATIC TRANSMISSION (4L30-E)
INTERMITTENT CONDITIONS
If the TECH1 displays a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this
DTC are present: the problem is most likely a faulty
electrical connection or loose wiring. Terminals
and
grounds should always be the prime suspect.
lntermittents rarely occur inside sophisticated
electronic components such
as the TCM.
Use the
DTC information to understand which wires
and sensors are involved.
When an
intermittent problem is encountered,
check suspect circuits for:
(1) Poor terminal to wire connection.
(2) Terminals not fully seated in the connector
body (backed out).
(3) Improperly formed or damaged terminals.
(4) Loose, dirty, or corroded ground connections:
HINT: Any time you have an intermittent in
more than one circuit, check whether the circuits
share a
common ground connection.
(5) Pinched or damaged wires.
(6) Electro-Magnetic Interference (EMI):
HINT:
Check that all wires are properly routed
away from spark plug wires, distributor wires,
coil, and generator. Also check
for improperly
installed electrical options, such as lights, 2-way
radios, etc. Use
the
F3: SNAPSHOT mode of the TECH 1 to help
isolate the cause
of an intermittent fault. The
snapshot
mode will record information before and
after the problem occurs. Set the snapshot
to
"trigger" on the suspect DTC or, if you notice the
reported
symptom during test drive, trigger the
snapshot
manually.
(1) NOTE: When TECH1 is plugged the shifts are
always
done at the maximum pressure. This
means
that if you do SNAPSHOT while driving
you will! notice firm shifts.
After the snapshot has been triggered, command
the TECH1 to play back the flow of data recorded
from each of the various sensors. Signs of an
intermittent fault in a sensor circuit are sudden
unexplainable jump in data values out of the
normal range.
CASE:
problem still not solved GOTO TCM MEM­
CAL REPLACEMENT.
•

•
, cCi" -.J )> I .... N
RELAY
& FUSE BOX
(FL-1, FL-2, FL-3)
THROTTLE BODYASM SPEED SENSOR
ECM:
ENGINE CONTROL
MODULE
TCM:
TRANSMISSION CONTROL
MODULE
TP :THROTTLE
POSITION
ICM
: IGNITION CONTROL
MODULE
)
ECM
ICM(CONT) FRONT
CONSOLE
MODESW
MAIN
CASE
,}
~H-32
FUSE BOX
(C-3,
C-4,C-8,
C-10,
C-14)
BRAKE
SW
KICK DOWN
SW
ACCELERATOR PEDAL
1-9 INDICATOR LIGHT
(POWER, WINTER) 1-1 WARNING BOX (AfT
OIL
TEMP )
CHECK TRANS.
C-92 DIAGNOSIS CONNECTOR C-9 DATA
LINK CONNECTOR
}
(') 0 2
2 m a ::IJ r-0 (') !4 0 2
" t .... C1l N l> c: a s: !4 n -4 ::IJ l> 2 rA s: c;; rA 0 2 ~ ~ 0 I m

... ......,.
AUTOMATIC TRANSMISSION (4L30-E) 7A-155
ON-VEHICLE SERVICE
CHECKING TRANSMISSION FLUID
LEVEL
1. Park the vehicle on level ground.
2. Apply the parking brake.
3. Place the automatic transmission in "Park" and
start the engine.
Allow the engine to idle for
two minutes.
4. With the brakes applied, move the shifter lever
through all the gear ranges, ending in "Park".
5. Remove the dipstick, Carefully touch the
dipstick with your finger to determine the
temperature of the fluid. (Fig. 7A-14)
• If the fluid is cool or warm (approximately
room temperature) or slightly higher (but
not too hot to touch), the fluid level should
be within the "Cold" range.
• If the fluid is hot, the fluid level should be
(A; within the "Hot" range.
6.
Cold Hot
Fig. 7A-14
• If the vehicle has just been driven for a long
period of time at highway speeds or in city
traffic in hot weather, wait 30 minutes for
the fluid to cool down before checking fluid
level.
If fluid level is low, add enough DEXRON®-m
Automatic transmission fluid to bring trans­
mission
to its proper fluid level through the
transmission oil filler tube.
NOTE:
The automatic transmission fluid level must be
checked
with the vehicle at normal AfT oil
operating temperature: 75 TO 85°C (167 TO
185°F)
measured with TECH1 scan tool.
Overfilling or underfilling could result in
damage
to the transmission.
• If fluid level is low, inspect the area around
the oil pan for leakage.
•
If the fluid smells burnt or is black, replace
it.
CHANGING TRANSMISSION FLUID
There is no need to change the transmission fluid
unless the transmission is used under one or more
of the following heavy duty conditions.
A: Repeated
short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Towing a trailer
If the vehicle is used under these conditions,
change the fluid every 20,000 miles (32,000 km.)
There is
no drain plug in the oil pan. Oil should be
extracted
with suitable suction device through the
filler tube. Alternately the fluid can be drained by
carefully removing the oil pan. Place a large drain
pan
under the oil pan, remove 13 bolts on the right,
left and front sides of the oil pan and loosen 3 bolts
on the rear side.
Drain
the fluid carefully.
Hold
the pan horizontally, remove the remaining 3
bolts and remove pan and gasket. Clean the oil pan
and
reinstall it . with a new gasket. It is also
recommended to replace the fixing bolts. Tighten
16 fixing bolts to 11 N·m (8 lb·ft.) torque.
MANUAL LINKAGE
~ INSPECTION
1. Make sure that when the shifter control lever is
shifted
from "P" to "L", a "clicking" can be felt
at each shift position. Make sure that the gear
corresponds
to that of the position plate
indicator.
2. Check to see if the shifter lever can be shifted
as
shown in Fig. 7A-15. jQ
~ Button must be pressed.
~ Button need not be pressed.
Fig. 7A-15

Rubber band
Fig. 7A-16c
Adjustment of shift lock cable (Fig. 7A-16d)
(1) Set IGN key in "LOCK" position and selector
lever
in "P" position.
(2)
Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 2.0 ± O.Smm
between rod on steering lock side and stopper.
Adjust cap as follows:
CD Hand turn nut (A) until it comes in contact
with bracket while pulling screw cap in
® Then turn nut (A) 2 reverse turns (2 mm) to
give slack to inner cable.
@ Lock inner cable by turning nut (8) while
holding nut (A) in place.
~~~ Torque N-m(lb-in) j 4 (35)
W NOTE:
Clean the cable threads and do not apply oil to
the threaded portions.
AUTOMATIC TRANSMISSION (4L30·E) 7A-157
Fig. 7A-16d
(3) Make sure of proper operation of shift lock
through checks as follows:
CD Selector lever shall not be moved out of "P"
position with IGN key in "Lock" position.
® Selector lever can be moved out of "P"
position with IGN key in "ON" position only
when brake pedal is depressed.
@ IGN key can be turned to "LOCK" position
only when selector lever is in "P" position
(key can be
pulled out).
If CD and @ fail, readjust cable. If ® fails, readjust
connector
wiring and brake pedal switch.
MODE SWITCH
1++1 REMOVAL
Preparation:
• Disconnect negative (-) battery cable.
• Place selector lever
in neutral.
~3. Heat protector
2. Selector lever
6. Mode switch
1. Cover
~
Fig. 7A-17

VALVE BODY ASSEMBLY (MAIN CASE)
1••1 REMOVAL
Preparation:
• Disconnect negative (-) battery cable.
• Remove exhaust protector and exhaust pipe.
1. Main case oil pan
• Remove sixteen 10 mm screws, main case
oil pan,
magnet and gasket.
• Drain fluid.
Refer
to "CHANGING TRANSMISSION
FLUID".
2. Oil filter
•
Remove three 13 mm screws, oil filter.
3. Manual detent
• Remove two 13 mm screws, roller and
spring assembly.
4. Wiring harness
• Disconnect wiring harness from band control
solenoid, shift solenoids and main
case 4 pin
connector.
Pull only on connectors, not on
wiring harness.
5.
Servo cover
• Remove four 13 mm screws, servo cover
and gasket.
6. Main case valve body
• Remove seven 13 mm valve body screws.
• Remove main valve body assembly with
manual valve link and transfer plate.
NOTE:
Note the position of link, with the long end into
valve, short end into range selector lever.
• Remove transfer plate gasket from main
case.
• Remove two check balls from main case.
I••IINSTALLATION
To install, follow the removal steps in the reverse
order,
noting the following points;
6. Main
case valve body
• Install two check balls (Fig. 7 A-29g).
• Inspect electrical 4 pin connector and seal of
main case. Replace if necessary.
• Install two guide pins into main case.
1®.1 Guide pin: J-25025-B
• Install
valve body complete assembly and
manual valve link.
NOTE:
Valve must be extended as the short end of
manual valve link is connected to the range
selector lever. Long end
of link goes into valve.
AUTOMATIC TRANSMISSION (4L30-E) 7A-167
• Install seven 13 mm screws (Fig. 7A-29h).
~~~ Torque N·m(lb·ft) I 20 (15)
5.
4.
• Remove two guide pins.
Fig. 7A-29g
Fig. 7A-29h
Servo cover
Check ball
• Install servo cover gasket, cover and four 13
mm screws.
Torque
N·mOb·ft) I 25 (18)
Wiring harness
• Connect harness to band control and shift
solenoids.
• Connect 4 pin connector to main case
connector.

7A-174 AUTOMATIC TRANSMISSION (4L30·E)
1•!•1 biSASSEMBLV
During the disassembly and reassembly of the
following components, perform the following:
• Wash each part thoroughly and blow air
through each oil passage and groove to
eliminate blockage.
• Seal rings, roll pins and gaskets should be
replaced
with new parts.
• When assembling the components, apply
DEXRON®-m Automatic Transmission Fluid
(ATF)
to each seal, rotating part and sliding
part.
• Do not dip those parts having a facing, such as
drive plate for clutch or brake, in the cleaner
when washing it with solvent.
Also, always wash
it with new ATF two or
three times after cleaning with solvent.
1. Torque converter (Fig. 7A-30)
l"i:\1 • Drain fluid from torque converter.
~ • Attach holding fixture to the transmission
and set it on holding fixture base (Fig. 7A-
31).
Holding fixture: J-8763-02
Fixture base: J-3289-20
w NOTE:
Do
not overtighten the tool, as case damage
may result.
Fig. 7A-31
2. 0-ring (Fig. 7 A-30)
•
Remove 0-ring from turbine shaft.
3. Mode switch and transmission harness (Fig.
7A-30)
•
Remove two 10mm screws, cover and
mode switch.
• Remove transmission harness.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Adapter case oil pan (Fig. 7 A-30)
•
Remove twelve 10mm screws, adapter oil
pan, and gasket.
• Remove oil filler tube.
Wiring harness (Fig. 7 A-30)
•
Disconnect electrical connections from
solenoids. Pull on connectors only, not on
wiring harness.
Adapter case valve body (Fig. 7A-30)
• Seven
13mm screws, adapter case valve
body assembly, transfer plate and two
gaskets.
• Remove wmng harness and 5 pin
connector.
Main case oil pan (Fig. 7 A-30)
•
Remove sixteen 10mm screws, main oil
pan, magnet, and gasket.
Oil filter· (Fig. 7 A-30)
•
Remove three 13mm screws, oil filter.
Manual detent (Fig. 7 A-30)
•
Remove two 13mm screws, roller & spring
and manual detent.
Wiring harness (Fig. 7 A-30)
•
Disconnect harness assembly from band
apply solenoid, shift solenoids and main
case 4 pin connector.
• Remove 4 pin connector.
Servo cover (Fig. 7 A-30)
•
Remove four 13mm screws, servo cover
and
~1asket.
Main case valve body (Fig. 7 A-30)
•
Remove seven 13mm valve body screws.
• Remove main valve body assembly with
manual valve link and transfer plate.
NOTE: Note
thE! position of link, with the long end into
valve, short end into range selector lever.
• Remove gasket transfer plate from main
case.
• Remove two check balls from main case.
13.
Servo Piston (Fig. 7A-32)
• Turn transmission to vertical position to drain
fluid. Return back
to horizontal position when
drained.
• Install servo piston spring compressor with
offset to the rear of case.
• Compress servo piston assembly.
• Remove servo piston retaining ring.
• Slowly release servo piston assembly.
• Remove tool.
1®.1 • Remove servo piston assembly, return spring,
and servo apply rod.
Servo piston spring compressor: J-23075
•

7A-184 AUTOMATIC TRANSMISSION (4L30-E)
~· Ensure free rotation of pump using rotation
tool.
16
Pump rotation tool: J-23082-01
-----16. Selective thrust washer
Fig. 7A-53
l'fil Overdrive end play measurement (Fig. 7A-54)
~ • Fit puller on turbine shaft.
• Position axial play checking tool on
converter housing mating face.
• Pull turbine shaft upwards with puller until
first resistance is met.
(Due
to weight of overdrive complete
assembly)
Maintain shaft in this position and set
indicator to zero.
• Pull turbine shaft further upwards with
puller. Read end play shown on indicator.
End
play mm (in) I 0.1 -0.8 (0.004-0.031)
1®.1 Turbine shaft puller: J-25022 and J-24773-1
J-24773·1
J-25022
Fig. 7A-54
15. Extension housing (Fig. 7A-55)
• Inspect extension housing oil seal and
replace if necessary (Fig. 7 A-56).
1®.1 Extension housing oil seal installer: J-36797
• Rotate transmission to horizontal position,
with valve body side down.
• Inspect parking wheel seal ring. Replace if
necessary.
• Install wheel parking lock assembly.
• Install
speed wheel and snap ring.
NOTE:
Use extra long nose pliers.
• Install
gasket onto extension assembly,
usin£1 a thin coating of oil.
• Install
extension housing assembly, and
align parking pawl shaft.
• Install actuator assembly into extension
assembly.
• Install
seven 8 mm hexagon socket head
screws.
• Remove axial play checking tool and puller. ~~~ Torque N-m(lb.ft) 32 (24) W NOTE: _ __:_ ___ __:___:__J_ _ __.::..:::....=_:..:.__ __
If end play is not correct, repeat selective
washer selection.

12. Main case valve body (fig. 7A-59)
• Install two check balls (Fig. 7A-60).
• Inspect electrical
connector and seal, replace
if necessary.
• Install electrical 4 pin connector/main case
and
wiring harness.
1®..1 • Install two guide pins into main case.
Guide pin:
J-25025-B
• Install valve
body complete assembly and
manual valve link.
W NOTE:
Valve must be extended as the short end of
manual valve link is connected to the range
selector lever. Long end of link goes into valve.
Fig. 7A-60
• Install
seven 13 mm screws.
~~~ Torque N·mOb·ft) I 20 (15)
• Remove two guide pins.
11.
Servo cover (fig. 7 A-59)
Check ball
• Install servo cover gasket, cover and four 13
mm screws.
~~~ Torque N·mOb·ft) I 25 ( 18)
10. Wiring harness (fig. 7A-59)
• Connect harness to band control and shift
solenoids.
9. Manual detent (fig. 7 A-59)
• Install roller and spring assembly with clip.
Install two 13 mm screws.
~~~ Torque N·mOb·ft) 20 (15)
AUTOMATIC TRANSMISSION (4L30-E) 7A-187
8. Oil filter (Fig. 7 A-59)
• Install oil filter, three 13 mm screws.
~~~ Torque N.m(lb·ft) I 20 (15)
7. Main
case oil pan (Fig. 7 A- 59)
• Install oil pan gasket, magnet, oil pan,
sixteen
10 mm screws.
~~~ Torque N·m(lb·in) I 11 (96)
6. Adapter case valve body (fig. 7 A-59)
• Inspect electrical connector and seal.
Replace
if necessary.
Install electrical five pin connector and
harness
assembly in bottom of adapter
case.
Install gasket, transfer plate, gasket.
• Install adapter case valve body complete
and seven 13 mm screws.
~~~ Torque N.m(lb.ft) I 20 (15)
5. Wiring harness (fig. 7A-59)
• Connect harness assembly to converter
clutch solenoid, and force motor.
4. Adapter case oil pan (fig. 7 A-59)
• Install oil pan gasket, oil pan, twelve 10 mm
screws.
~~~ Torque N·mOb·in) 11 (96)
• Rotate transmission, with bottom pan
facing
down.
• Install seal ring, oil filler tube, 10 mm screw.
~~~ Torque N·mOb·in) I 13 (113)
3. Mode switch and transmission harness
(Fig. 7A-61).
• Install transmission harness.
• Install mode switch, shield and two 10 mm
screws.
• Adjust using setting tool.
Refer to "MODE SWITCH" in this section.
~~~ Torque
Selector shaft nut
10 mm screw
N·mOb·ft)
23 (17)
13 (113 lb·in)