light ISUZU TROOPER 1998 Service Repair Manual

7A±47 AUTOMATIC TRANSMISSION (4L30±E)
36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
242RS003
47. Rotate case to horizontal position, valve body side
facing up.

Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).NOTE: Insert wire in the center of the spring pin to
prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.

Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
Torque: 22 Nwm (2.2 kg´m/16 lb ft)

TRANSMISSION CONTROL SYSTEM (4L30±E)7A1±9
Winter Drive Mode
1.Operation
The winter switch will operate when switched on after
all of the following conditions are present:
a. The gear select position is ªDº, ªNº, ªRº and ªPº
range.
b. Vehicle speed is 7 mph (11 km/h) or less.
c. Transmission oil temperature is 120
C (248
F) or
less.
d. Kickdown switch is off.
e. Accelerator opening is at 8% or less.
2.Cancel Release
1. Cancellation by driver
a. Turning off the winter drive mode switch
b. Shifting select position to ª3º, ª2º, or ªLº (Winter
drive mode is not canceled by selecting ªDº, ªNº,
ªRº, or ªPº)
c. Ignition key is turned off.
2. Automatic cancellation
a. When vehicle runs at 21mph (34 km/h) or more
for 1 second or more
b. When transmission oil temperature reaches
140
C (284
F) or above
NOTE: The mode returns to normal drive mode or power
drive mode after the winter drive mode is canceled.
Backup Mode
If a major system failure occurs which could affect safety
or damage the transmission under normal vehicle
operation, the diagnostic system detects the fault and
overrides the Powertrain Control Module (PCM).
The ªCHECK TRANSº light flashes to alert the driver, and
the transmission must be manually shifted as follows:
Select lever position
Gear Ratio Selected
D4 (Fourth)
Manual 34 (Fourth)
Manual 23 (Third)
Manual L1 (First)
RReverse
Shifts are firmer to prevent clutch slip and consequent
wear. The fault should be corrected as soon as possible.

7A1±10
TRANSMISSION CONTROL SYSTEM (4L30±E)
Functions of Input / Output Components
ComponentsFunction
Speed sensor
(fixed to transmission
(T/M))Senses rotation of output shaft and feeds the data to Powertrain Control Module
(PCM).
Throttle position sensor
(TPS)
(fixed to engine)Senses the extent of throttle valve opening and the speed of the throttle valve
lever motion to open the valve. Feeds the data to PCM.
I
N
Brake Switch (SW)
(fixed to brake pedal)Senses whether the driver has pressed the brake pedal or not and feeds the
information to PCM.
N-
P
U
Kickdown SW
(fixed to accelerator pedal)Senses whether the driver has pushed the accelerator pedal fully or not, and
feeds the information to PCM.
U
TMode SW (fixed to T/M)Senses the select lever position, and feeds the information to PCM.

S
I
Power drive SW
(fixed to front console)Senses whether the driver has selected the power mode, and feeds the informa-
tion to PCM.
I
G-T/M oil temp. sensorSenses the T/M oil temperature and feeds the data to PCM
N
A
L
Engine coolant tempera-
ture sensorSenses the engine coolant temperature, and feeds the data to PCM.
LEngine speed signalFeeds the signals monitoring engine speed to PCM from crank angle sensor.
Air conditioning informationSenses whether the air conditioner has been switched on or not, and feeds the
information to PCM.
Winter switch (fixed to front
console)Senses whether the driver has selected the winter mode, and feeds the informa-
tion to PCM.
Cruise controller * (Over-
drive OFF signal)Downshift takes place when Overdrive OFF signal is received from auto cruise
control unit.
S
Shift solenoid A, BSelects shift point and gear position suited to the vehicle running condition on
the basis of PCM output.
O
S
O-
L
Band apply solenoidControls oil flow suited to the vehicle running condition on the basis of PCM out-
put.
O
U
T-
P
E-
N
O
Torque Converter
Clutch solenoidControls clutch engagement/disengagement suited to the vehicle running condi-
tion on the basis of PCM output.
P
U
T

O
I
DForce motor
(Pressure regulator
valve)Adjusts the oil pump delivery pressure to line pressure suited to the vehicle run-
ning condition on the basis of PCM output.

S
I
Power drive mode lampInforms the driver whether the vehicle is in power mode or not.
I
G-Winter drive mode lampInforms the driver whether the vehicle is in winter mode or not.G
N
A
L
T/M monitor lamp
(ªCHECK TRANSº)Informs the driver of failure in the system.
LATF warning lampLights when ATF oil temperature rises.
ABS signal *When the select lever is at ªReverseº or ªLº range, sends a signal to the ABS
controller as one of the ABS control conditions.
* If equipped

7A1±22
TRANSMISSION CONTROL SYSTEM (4L30±E)
connection or loose wiring. Terminals and grounds should
always be the prime suspect. Intermittents rarely occur
inside sophisticated electronic components such as the
PCM.
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 Tech2 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 ªtriggerº on the suspect DTC. If you
notice the reported symptom during the test drive, trigger
the snapshot manually.
After the snapshot has been triggered, command the
Tech2 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.
Transmission And PCM Identification
The chart below contains a list of all important information
concerning rear axle ratio, Powertrain Control Module
(PCM), and transmission identification.
VEHICLE
Rr axlePCMTRANSMISSION
TypeEngine
Rr axle
RatioISUZU Parts No.Calibration
CodeIsuzu Part No.Model Code
Isuzu /
Trooper3.2L V64.555
8±16254±949±0
8±16254±749±0
8±16253±989±0
G208±96018±272±3FP (4X4)

7A1±28
TRANSMISSION CONTROL SYSTEM (4L30±E)
DTC P0560 System Voltage Malfunction
StepActionYe sNo
11. Install the scan tool.
2. With the engine ªoffº, turn the ignition switch ªonº.
NOTE: Before clearing DTC(s), use the scan tool to record ªFailure
Recordsº for reference, as data will be lost when the ªClear Infoº
function is used.
3. Record the DTC ªFailure Recordsº. Note: If any other DTCs
are present, refer to their applicable diagnostic charts before
continuing.
4. Using the J±39200 DVOM, measure the battery voltage
across the battery terminals. Record the measurement for
future reference.
Is the voltage higher than 10.5 volts?
Go to Step 2
Go to Engine
Electrical in
Engine section
2Start the engine and warm to normal operating temperature.
Is the generator/check engine light ªonº?Go to Starting
and Charging
System in Engine
section
Go to Step 3
31. Increase the engine speed to 1,000±1,500 rpm.
2. Observe scan tool system voltage.
Is the system voltage within 13±15 volts.
Go to Step 4
Go to Starting
and Charging
System in Engine
section
41. Turn the ignition switch ªoffº.
2. Disconnect the J1(RED) and J3 (BLUE) PCM connector
(additional DTCs will set).
3. With the engine ªoffº, turn the ignition switch ªonº.
4. Using the J39200 DVOM, measure the battery voltage input at
PCM connector terminals J1±A4 and J3±E16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J1±A4 and J3±E16 that
is greater than 0.5 volts?
Go to Step 5Go to Step 6
5Repair the high resistance condition in circuit WHT.
Was the circuit repaired?
Go to Step 10Ð
61. Disconnect the J3 (BLUE) PCM connector.
2. Measure the ignition voltage input at PCM connector terminals
J3±E16 and J3±F16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J3±E16 and J3±F16 that
is greater than 0.5 volts?
Go to Step 7Go to Step 8
7Repair the high resistance condition is circuit RED/BLU.
Was the circuit repaired?
Go to Step 10Ð
8Check PCM connector terminals J1±A4, J3±E16 and J3±F16 for
bent, damaged, or backed out connector pins. Also check for
weak terminal tension.
Was a problem found?
Go to Step 10Go to Step 9

TRANSMISSION CONTROL SYSTEM (4L30±E)7A1±43
DTC P0719 TCC Brake Switch Circuit High (Stuck On)
StepActionYe sNo
11. Install the scan tool.
2. With the engine ªoffº, turn the ignition switch ªonº. If ABS code
is set, check applicable fuse.
NOTE: Before clearing DTC(s), use the scan tool to record ªFailure
Recordsº for reference, as data will be lost when the ªClear Infoº
function is used.
3. Record the DTC ªFailure Recordsº.
4. Apply then release the brake pedal.
Does the scan tool display ªTCC Brake Switchº as ªclosedº with
the brake pedal applied, and then display ªopenº when the brake
pedal is released?
Go to Diagnostic
Aids
Go to Step 2
21. Connect the test light to ground.
2. Back probe ignition feed circuit terminal B13±1 at the brake
switch.
Is the test light ªonº?
Go to Step 3Go to Step 4
31. Connect the test light to ground.
2. Back probe circuit terminal B13±4 at the brake switch.
Is the test light ªoffº?
Go to Step 7Go to Step 5
4Repair the open in battery feed circuit terminal B13±1 to the brake
switch.
If fuse is open, check circuit terminal B13±4 for a short to ground.
Is the repair complete?
Go to Step 13Ð
5Disconnect brake switch connector B±13 and ignition switch ªonº.
Is the test light ªonº?
Go to Step 8Go to Step 6
6Check the brake switch short (B13±1 and B13±4).
Was a problem found?
Go to Step 9Go to Step 10
7Check circuit terminal B13±4 for a short to voltage.
Ignition switch ªonº.
Is the test light ªonº?
Go to Step 8Go to Step 10
81. Disconnect the J3 (BLUE) PCM connector.
2. Check circuit terminal B13±4 for a short to voltage.
Was a problem found?
Go to Step 13Go to Step 10
9Replace the brake switch.
Is the replacement complete?
Go to Step 13Ð
101. Turn the ignition ªoffº.
2. Reconnect the J3 (BLUE) PCM connector.
3. Turn the ignition ªonº.
Does the scan tool display ªTCC Brake Switchº as ªopenº with the
brake applied, then display ªclosedº with the brake pedal
released?
Go to Diagnostic
Aids
Go to Step 11
11Check the PCM for faulty or intermittent connections.
Was a problem found and corrected?
Go to Step 13Go to Step 12

7B±20MANUAL TRANSMISSION
220RW095
Legend
(1) Release Bearing and Shift Fork
(2) Clutch Housing
(3) Front Cover
(4) Snap Ring
(5) Snap Ring
(6) 1st and 2nd Switch
(7) Drain Plug
(8) Backup Light Switch
(9) Transmission Case(10) Filler Plug
(11) Gear Control Rod
(12) Reverse Restrict Pin
(13) Oil Receiver Pipe
(14) Transfer Adapter
(15) Plug (6VE1) or Neutral Switch (4JX1)
(16) Gear Control Box
(17) Shift Lever Housing
(18) Oil Seal
(19) Plug

MANUAL TRANSMISSION7B±21
Disassembly
1. Remove the drain plug and filler plug.
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket.
(6VE1)
220RW007
2. Remove the clutch release bearing and shift fork.
1. Remove the clutch release bearing (3) from the
front cover.
2. Remove the split pin (4). Remove the shaft from
the under. Remove the shift fork (5).
220RW086
3. Remove the switch.
1. Remove backup light switch (6) and gasket.
2. Remove neutral switch (7) and gasket (4JX1).
3. Remove 1st and 2nd switch (8) and gasket.
(4JX1)
220RW093
4. Remove the clutch housing.
1. Remove the 9 bolts.
241RW001

7B±66MANUAL TRANSMISSION
38. Install clutch housing.
1. Install the clutch housing to the transmission
case.
Torque: 36 N´m (3.7 kg´m/27 lb ft)
NOTE: Tighten the all bolts evenly.
241RW001
39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 N´m (4.0 kg´m/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
Torque: 44 N´m (4.5 kg´m/33 lb ft)
5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 N´m (3.8 kg´m/27 lb ft)
(4JX1)
220RW093
40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
220RW086

MUA MODEL 7B1 – 53
Front Propeller Shaft
Remove the splined yoke flange bolt at the transfer case
side.
Do not allow the splined yoke to fall away from the front
propeller shaft.
If the splined yoke should fall away from the front
propeller shaft, align the setting marks
3on the splined
yoke 1and the propeller shaft 2to reassemble the two
parts.
The setting marks 3are punched circles approximately 3
mm (0.12 in) in diameter.
TDC Sensor (4JA1TC Model)
Disconnect the TDC sensor from the transmission
housing.
Harness Connector
Disconnect the 4WD switch connectors, back up light
switch connector and the speedometer sensor connector.
220R200001
Slave Cylinder
Remove the slave cylinder from the transmission case.
220LV019
Engine LIfting Hanger
1. Attach the engine lifting hanger to the front portion of
the engine.
2. Attach the lifting wire to both ends of the engine
lifting hange.