2004 ISUZU TF SERIES oil pressure

7A3-38 ON-VEHICLE SERVICE (AW30 –40LE)

2. Remove the oil strainer assembly.




244RY 00003
3. Disconnect the solenoid wiring connectors from the
solenoids.
4. Remove the twenty bolts from the valve body.
5. Remove the valve body assembly and pressure control solenoid.

After removing valve body assembly from the
transmission case, loosen the solenoid clamp
bolt and remove the pressure control solenoid
from the upper valve body assembly.
Also disconnect the harness connector from the
pressure control solenoid.

NOTE:

Two or more persons are required for removal and
installation of the valve body assembly and pressure
control solenoid.
 The check valve assembly (1) and the C0
accumulator piston springs (2) will fall from the
transmission case during removal of valve bod
y
assembly.
Protect these parts from damage. The B0 (3), C2 (4),
and B2 (5) accumulator piston and springs may also
fall free and must be protected.



244RY00018







244RY00006

7A4–14 UNIT REPAIR (AW30–40LE)
10. Install the solenoid wiring.
Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).
24 9RY 0 0011
24 9RY 0 001 2
11. Install a new oil strainer assembly with gaskets.
24 4RY 0 0002
Install the oil strainer with the gaskets to the valve
body. Tighten the four bolts.
Torque: 10 N·m (87lbin)
24 4RY 0 0003

7A4–66 UNIT REPAIR (AW30–40LE)
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048
24 8RY 0 000 3
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
24 8RY 0 004 2
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from
forward clutch drum.
Inspection and Repair
1. Check forward clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031
2. Check forward clutch drum bushing.
Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 in)
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
24 8RY 0 0043
3. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.

7A4–132 UNIT REPAIR (AW30–40LE)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J–37227
Holding fixture
J–3289–20
Holding fixture base
J–37228
Oil pan seal cutter
J–23327–1
Spring compressor
J–9617
Oil seal installer; oil
pump
J–37233
Spring compressor; OD
brake piston
J–29770–A
Oil pressure gauge
J–25048
Spring compressor
J–37236
Reaction sleeve puller;
first and reverse brake
J–37237
Piston puller; first and
reverse brake
J–37232–2
Oil seal installer;
manual valve shaft seal
installer & remover
J–35467
Onennway clutch
testing tool; torque
converter ILLUSTRATIONTOOL NO.
TOOL NAME

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

7A1-6 CONSTRUCTION AND FUNCTION
ELECTRONIC CONTROL COMPONENTS LOCATION

4WD Only 4WD Only
Instrument panel (Meter)







Speed meter (2WD Only)
Shift position indicator lamp
POWER DRIVE, 3rd START
indicator lamp
A/T OIL TEMP indicator lamp
CHECK TRANS indicator lam
p

Brake pedal





Brake Switch
Select lever








Power Drive
, 3rd Start select switch
Transmission Control Module (TCM)
Electrical source






Ignition
Battery voltage
Speed sensor
Turbine sensor
Inhibitor switch
ATF thermo sensor
High clutch oil pressure switch
2-4 brake oil pressure switch
Low & Reverse brake oil pressure
switch
Line pressure solenoid
Low clutch solenoid
High clutch solenoid
2-4 brake solenoid
Low & Reverse brake solenoid
Lock-up solenoid
Transmission
Transfer Control Module
Transfer




4L mode switch
Engine




Engine speed sensor
Throttle Position Sensor


Engine Control Module (ECM)
Data link connector

7A1-8 CONSTRUCTION AND FUNCTION
STRUCTURE AND FUNCTION OF COMPONENT
TORQUE CONVERTER (WITH LOCK-UP FUNCTION)

The torque converter is a device for transmitting the engine torque to the transmission. It transmits power
by means of oil when the lock-up is disengaged and by means of a lock-up piston when it is engaged.

The torque converter is of the symmetrical, three-element, single-stage, two-phase type.

As shown in the drawing, the symmetrical three-elements refer to three elements (components) consisting
of impeller (1), turbine (2) and stator (3) that are arranged symmetrically (figure 5).

"Single-stage" means that there is only one turbine as an output element; "two-phase" means that the
pump impeller acts as a torque converter when the turbine speed is comparatively low, and as a fluid
coupling when the speed is high.


















1. Pump Impeller
2. Turbine Runner
3. Stator














1. Pump Impeller
2. Turbine Runner
3. Stator
4. Converter Cover
5. One-way Clutch
6. Lock-up Piston
7. Torsion Damper

Figure 5. Torque Converter
Figure 6. Construction of Torque Converter

Lock-up mechanism

"Lock-up" refers to a fixed state of the lock-up piston inside the torque converter and thus connects the
engine directly to the transmission.

The hydraulic pressure for the lock-up control is supplied from two circuits.

When the lock-up is disengaged (Figure 7)

When the lock-up is disengaged, the torque converter operating pressure is supplied from the oil passage
(A) to between the cover and the lock-up piston, and separates the lock-up piston clutch facing and
converter cover.

As a result, the engine drive power is transmitted from the converter cover to the pump impeller, the ATF
and to the turbine. The torque converter function as a fluid connector in this condition.

The torque converter operating pressure is supplied from the oil passage (A), passes through the oil
passage (B).

When the lock-up is engaged (Figure 8)

When the lock-up is engaged, the torque converter operating pressure is supplied from oil passage (B) to
the oil pump impeller, turbine, then to the stator side. The oil between the lock-up piston and converter
cover is drained.

Since the force acting on the right side of the lock-up piston is greater than force on the left side, it
connects the lock-up piston clutch facing with the converter cover, thereby increasing the transmission
efficiency.