2004 ISUZU TF SERIES brake sensor

7A2-12 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Functions of Input / Output Components
Component Function
Transfer low signal Detects the transfer High/Low position.
OD Cancel signal Detects whether the cruise control unit is judged OD cancel mode.
Output revolution sensor
(Transmission) Detects the vehicle speed.
Input revolution sensor
(Transmission) Detects the input revolution (OD direct clutch drum revolution).
Engine revolution sensor Detects the engine revolution with CAN.
Throttle position signal Detects the throttle opening rate with CAN.
Neutral start switch Detects the select lever position.
Pattern select switch Detects whether the driver has selected "NORMAL" or "POWER" mode.
Brake lamp switch Detects whether the driver has pressed the brake pedal or not.
Oil temperature sensor Detects the oil temperature.




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Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.
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/
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u t Data link connector When connected with Tech2 or tester, can communicate the data for function
check, etc.
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle running condition on the
basis of TCM output.
Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running condition on the basis of TCM output.
Pressure control solenoid
STH Adjusts throttle pressure by energizing current of linear pressure control solenoid
to prevent the shift shock and to obtain shift smoothly.
"CHECK TRANS" lamp When trouble has occurred to throttle position sensor, vehicle speed sensor, or
solenoid, "CHECK TRANS" lamp is blinked to warn the driver. If also displays the
trouble code.
A/T OIL TEMP warning
lamp Lights when ATF oil temperature rises. (Turned on at greater than 146


C
(295

F). Turned off at less than 132

C (270

F).
POWER lamp Lights when POWER MODE detected.



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3rd Start lamp Lights when 3rd Start MODE detected.
C
o
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e r Transmission Control
Module (TCM) Based on the signal from each switch and sensors, judges necessary shift point
and lock-up operation, and send signal to each solenoid.

7A2-22 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

TRANSMISSION DATA
ITEM UNIT ENGIN RUNNING AT IDLE
Current Gear 1 st/2 nd/3 rd/4 th 1 st
Target Gear 1 st/2 nd/3 rd/4 th 1 st
Vehicle Speed km/h 0 km/h
AT Output Speed (Automatic Transmission) RPM 0 RPM
AT Input Speed (Automatic Transmission) RPM 675725 RPM
Engine Speed RPM 675725 RPM
Throttle Position Sensor Signal % 0.007.00%
AT Oil Temperature (Automatic Transmission) C Depends on conditions
TCM Status Transfer Low /Transfer High Transfer HI
Desired PC Solenoid Pressure (STH) kPa 34.397.0 kPa
Desired PC Solenoid Current (STH) mA 8351020 mA
PC Solenoid Actual Current (STH) mA 8351020 mA
Gear Ratio : 1 Depends on uper hood
TCC Slip Speed RPM 0 RPM
Shift Position Actual P/R/N/L/2/3 P
Inhibitor Switch P/R/N/L/2/3 P
Transmission Check Light On/Off Off
AT Oil Temperature Lamp (Automatic
Transmission) On/Off Off
3 rd Start Lamp On/Off Off
Power Lamp On/Off Off
Shift Solenoid S1 On/Off On
Shift Solenoid S2 On/Off On
Shift Solenoid S3 On/Off Off
Diag Switch Condition On/Off Off
Power Switch On/Off Off
Brake Switch On/Off Off
Cruise Switch On/Off Off
4L Signal On/Off Off
3 rd Start Switch On/Off Off
Coolant Temperature C Depends on conditions
Torque Request (timing Retard) CA 0 CA
Garage Shift Mode On/Off Off
CAN TPS % 0.00%
CAN Signal Valid Counter (ECM)
— 0  255
CAN Signal Valid Counter (TCM) — 0  255

ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
TRANSMISSION
ON-VEHICLE SERVICE (AW30–40LE)
CONTENTS

Service Precaution .................................................
7A3-2
Location of Clutch, Brake, One-Way Clutch
and Solenoid ........................................................
7A3-3
Operation of Clutch, Brake and One-Way
Clutch ....................................................................
7A3-4
Trnasmission Indentification ..............................
7A3-4
Speed Change and Lock-Up Pattern ...............
7A3-5
Overdrive and Lock-Up Operating
Conditions ............................................................
7A3-5
Diagnosis .................................................................
7A3-6
Basic Troubleshooting ........................................
7A3-6
Manual Shifting Test ...........................................
7A3-12
Stall Test ..............................................................
7A3-12
Time Lag Test .....................................................
7A3-13
Hydraulic Test ......................................................
7A3-14
Road Test .............................................................
7A3-15
Shift Pont Chart and Lock-Up Point Chart ..........
7A3-19
Shift Pont Chart ...................................................
7A3-19
Lock-Up Point Chart ...........................................
7A3-20
Transmission Fluid Level and Condition .............
7A3-21
Inspection .............................................................
7A3-21
ATF Replacement ..................................................
7A3-22
Inspection .............................................................
7A3-22
Neutral Start Switch (Mode Switch) .....................
7A3-23
Inspection .............................................................
7A3-23
Removal ...............................................................
7A3-23
Installation ............................................................
7A3-23
Brake Signal ............................................................
7A3-24
Inspection .............................................................
7A3-24
Input and Output Revolution Sensor ....................
7A3-25
Inspection .............................................................
7A3-25
Pattern Select Switch .............................................
7A3-25
Inspection .............................................................
7A3-25
Solenoid ...................................................................
7A3-26
Inspection .............................................................
7A3-26

ATF Temperature Sensor ......................................
7A3-27
Inspection .............................................................
7A3-27
Select Lever ....................................................... 7A3-28 Remove or Disconnect .......................................
7A3-28
Install or Connect .................................................
7A3-29
Shift Cable ......................................................... 7A3-31
Remove or Disconnect .......................................
7A3-31
Install or Connect .................................................
7A3-32
Torque specifications ..........................................
7A3-33
Transmission Control Module (TCM) ...................
7A3-34
Removal ................................................................
7A3-34
Installation .............................................................
7A3-34
Shift Solenoid and Lock-Up Solenoid ...................
7A3-35
Removal ................................................................
7A3-35
Installation .............................................................
7A3-36
Valve Body Assembly and Pressure Control Solenoid .................................................
7A3-37
Removal ................................................................
7A3-37
Installation .............................................................
7A3-39
Rear Oil Seal (Adapter Housing, 4

4) .................
7A3-40
Removal ................................................................
7A3-40
Installation .............................................................
7A3-40
Rear Oil Seal (Extension Housing, 4
2) ..............
7A3-41
Removal ................................................................
7A3-41
Installation .............................................................
7A3-41
Transmission Assembly .........................................
7A3-42
Transmission and Associated Parts .................
7A3-42
Removal ................................................................
7A3-43
Installation .............................................................
7A3-46
Major Components ..............................................
7A3-50

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-43

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.
3. Remove front propeller shaft.(4WD only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
5. Remove the middle exhaust pipe.



RTW37ASH0001

6. Disconnect the transfer harness connectors and the
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
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).
7. Support transfer case with a transmission jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.






P1010010
11. Discinnect the transmission harness connectors
and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.

UNIT REPAIR (AW30–40LE) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

7A4–10 UNIT REPAIR (AW30–40LE)
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C–2).
Remove accumulator pistons and springs from
transmission case.
24 0RY 0 001 0
10. Applying compressed air to the oil hole, remove the
B–0 accumulator piston and spring.
24 0RY 0 0011
11. Remove the C–0 accumulator piston.
24 0RY 0 0012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4
4).
Remove the snap ring from the output shaft.
Remove the rotor and key.
2 47R20 0002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4
2).
Remove the snap ring from the output shaft.
Remove the speedometer sensor drive gear, and
ball.

CONSTRUCTION AND FUNCTION 7A1-1

SECTION 7A1
CONSTRUCTION AND FUNCTION
TABLE OF CONTENTS
PAGE
DESCRIPTION ..............................................................................................................................7A1- 3
CONSTRUCTION ....................................................................................................................7A1- 3
MAIN DATA AND SPECIFICATION .....................................................................................7A1- 4
NUMBER PLATE LOCATION ...............................................................................................7A1- 5
ELECTRONIC CONTROL COMPONENTS LOCATION ..................................................7A1- 6
TRANSMISSION CONTROL UNIT (TCM) PERIPHERAL CIRCUIT ..............................7A1- 7
STRUCTURE AND FUNCTION OF COMPONENT ...........................................................7A1- 8
TORQUE CONVERTER (WITH LOCK-UP FUNCTION) ..................................................7A1- 8
OIL PUMP .................................................................................................................................7A1- 9
INPUT SHAFT ..........................................................................................................................7A1- 10
OUTPUT SHAFT ......................................................................................................................7A1- 10
GEAR SHIFTING MECHANISM ............................................................................................7A1- 10
CONTROL VALVE ...................................................................................................................7A1- 14
OIL PASSAGE .........................................................................................................................7A1- 19
PARKING FUNCTION .............................................................................................................7A1- 20
INHIBITOR SWITCH ...............................................................................................................7A1- 21
TURBINE SENSOR .................................................................................................................7A1- 22
SPEED SENSOR .....................................................................................................................7A1- 22
THROTTLE POSITION SENSOR (TPS) .............................................................................7A1- 23
ENGINE SPEED SENSOR (=TDC SENSOR) ....................................................................7A1- 23
BRAKE SWITCH ......................................................................................................................7A1- 24
MODE SELECT SWITCH .......................................................................................................7A1- 24
TRANSMISSION CONTROL MODULE (TCM) ..................................................................7A1- 25
CONTROL MECHANISM ............................................................................................................7A1- 26
CONTENT OF FUNCTION AND CONTROL ......................................................................7A1- 26
CONTROL ITEM, INPUT AND OUTPUT .................................................................... 7A1- 29
LINE PRESSURE CONTROL ..................................................................................... 7A1- 30

CONSTRUCTION AND FUNCTION 7A1-3

DESCRIPTION
CONSTRUCTION



































1 Converter Housing 6 Low Clutch 11 Oil Pump
2 Torque Converter 7 Low & Reverse Brake 12 Control Valve
3 High Clutch 8 Output Shaft 13 Low One-way Clutch
4 Reverse Clutch 9 Extension Housing 14 Parking Gear
5 2-4 Brake 10 Input Shaft

Figure 1. Construction of Automatic Transmission

The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module
(TCM). There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift
Control: DESC) using a duty cycle type solenoid, which ensures high shift quality.
This transmission also controls learning and constantly checks the time of each clutch and brake required for
the speed change to match this time with the target value for the optimum speed change.

The TCM will automatically select the most appropriate shift points and lock-up points depending on the
throttle opening angle, the vehicle speed and the vehicle load.
If any trouble arises in the vehicle sensor, throttle sensor, solenoid, etc., the fail-safe control function is
activated to keep the running performance.
Problems with the sensors, the solenoids can be quickly detected with the self diagnosis procedure described
in this manual.

The JR405E automatic transmission consists of the torque converter, the oil pump, the input shaft, the out put
shaft, the planetary gears and the control valve.
The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two
multiple plate brakes and a one-way clutch.
2WD
4WD