2004 ISUZU TF SERIES clutch

TRANSFER CASE 7D-21

Oil Pump


Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play


Set a dial indicator to the clutch hub to be measured.


Move the clutch hub as far as possible to both the
right and the left.

Note the dial indicator reading.


If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch hub spline play
Standard : 0 – 0.1 mm (0 – 0.004 in)
Limit : 0.2 mm (0.008 in)

226RS042
Bearings
1.
Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2.
Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.




Ball Bearing Play
1.
Use a dial indicator to measure the ball bearing play.
2.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)


226R3043

Synchronizers
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together as
originally assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:


Teeth for wear, scuffs, nicks, burrs or breaks.


Keys and springs for wear, cracks or distortion,
replace if these conditions are present.


If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace
the component.

7D-22 TRANSFER CASE

Block Ring and Insert Clearance
1.
Use a vernier caliper to measure the clearance
between the block ring and the insert.
2.
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.

Block ring and insert clearance
Standard : 3.86 – 4.14 mm (0.152 – 0.163 in)
Limit : 4.9 mm (0.193 in)

226RS037

2WD-4WD Synchronizer (3-Cone)
1.
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2.
If the measured value exceeds the specified limit,
the 2WD-4WD synchronizer assembly must be
replaced.
Block ring and dog teeth clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)





226R300019

Clutch Hub and Insert Clearance
1.
Clutch Hub and Insert Clearance
2.
Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
3.
If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01-0.19 mm (0.0004-0.0075 in)
Limit : 0.3 mm (0.012 in)


226RS038

Detent Springs
1.
Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.

TRANSFER CONTROL SYSTEM 7D1-35
3.
Shifting from 4H to 4L
3-1 When the 4L indicator flashes at 2Hz
When shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is
completed. The phases of the engaged splines may sometimes deviated preventing completion of shifting.
By correcting the deviation of phases, shifting is completed.

Step 3-1:
(In case of AT): Set the select bar of the transmission to the D position.
(In case of MT): Set the lever of the transmission to a position allowing running and engage the clutch
gently.
At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is
completed.

3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)
This condition occurs when torsional torque has been generated between the transmission and road surface
and the transfer standby mechanism cannot absorb it completely.

Step 3-2:
Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at
this time.)

3-3 When the 4L indicator flashes at a frequency of 4Hz
Shifting from 4H to 4L is restricted.
When the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:
3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).

Restriction on operation (Except 4JA1-LT)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM
position).
Requirement to restrict the speed: Vehicle should be in stop.
For the reason of the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 – R), the time to wait
becomes longer.
Waiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues 3
minutes. After that, the waiting time increases up to 3 minutes in 2 minutes.
When it is clear that the above condition has continued and reduction of waiting time is desirable, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommendable
(MT) should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

7D1-36 TRANSFER CONTROL SYSTEM
Restriction on operation (4JA1-LT)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, and TM position).
Requirement to restrict the speed: Vehicle should be in stop.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.
Requirements for permission of restriction on T/M position restriction:
should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

Note: Don’t’ accelerate engine speed a the time of this operation.

Step 3-3:
Stop the vehicle. (Close the accelerator and decrease the engine speed to below L4: 3000rpm, V6:
2000rpm.)
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position. (Stepping on the clutch is
recommendable.) Push the 4L button.
If shifting operation is not completed (the lamp flashes at 2Hz), perform the step 3-1.

4. Shifting from 4L to 4H
4-1 When 4L indicator continues flashing at 2HZ
When shifting from 4L to 4H, the 4L indicator continues flashing at 2Hz until the shifting in the transfer case is
completed. Phases of engaged splines may deviate and the operation may not completed in some cases.
Shifting is completed by correcting the deviation of the splines.

Step 4-1: (same as step 3-1)
(In case of AT): Set the transmission select lever to the D position.
(In case of MT): Shift the transmission lever to a position allowing running and engage the clutch
gently.

4-2 When the indicator continues flashing at 2Hz for 10 seconds and then keeps on at 4L again (AT
vehicle)
This condition occurs when torsional torque has generated between the transmission and the road surface
(use of the parking position on a slope) and resistance against the separation of the driving force cannot be
fully by the waiting mechanism of the transfer.
Shifting is possible by using the brake also at the neutral position of the transmission

Step 4-2: (Same procedure
as the step 3-2)
Set the transmission select lever to the N position.
(Leaving the brake lever and stepping it again is recommendable.)

4-3 When the 4L indicator flashes at 4HZ
Shifting from 4L to 4H is restricted.
When the vehicle is running, transmission lever is at the running range, and the engine speed is high, the
transfer 4L cannot be shifted to 4H.

TRANSFER CONTROL SYSTEM 7D1-37
Step 4-3: (Same procedure as the step 3-3)
Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or
below).
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position (stepping on the clutch lever is
recommendable).
Push the 4H button.
If the shifting is not completed (indicator flashes at 2Hz), go to the step 4-1.

5. When shifting from 4H or 4L to neutral
(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz
The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If
torsional torque has accumulated between the transmission and road surface, separation may be difficult.

Step 5-1:
If the operation is not completed, execute the step 7 for confirmation.
(In case of AT): Set the transmission select lever to the D position.
After confirming that the gears are at the neutral position, return the lever to the N
position.
(In case of MT): Set the transmission lever to a vehicle running position and engage the clutch gently.
After confirming that the gears are at the neutral position, return the lever to the
neutral position

5-2 When the neutral indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H).
If the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is
impossible (restriction on operation).

Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch
is recommended).
Keep pushing the 2H and 4L button for 10 second.
Follow the start procedure for confirmation. (Confirmation of drive force not transferred; same as in the
step 5-1)
After the confirmation, set the transmission to the neutral position in case of MT or to the neutral
position in case of AT.

7D1-38 TRANSFER CONTROL SYSTEM
6. When shifting from neutral to 2H, 4H or 4L
6-1 When the 4L indicator or 4WD indicator flashes at 2Hz
Indicator flashing at 2Hz indicates that the engagement of the splines has not completed because of
deviation of the spline phases. By eliminating such a deviation, shifting is completed (same as in the step 3-1
and 4-1).
6-2 When the 4L indicator or 4WD indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation to 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (3000rpm or more) while the vehicle is
running, operation from neutral of the transfer to the 4L or 4H (including 2H) is impossible (restriction on
operation).

Step 6-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch
is recommended).
Keep pushing the4H or 4L or 2H button for 10 second.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)
CONTENTS

Service Precaution .................................................
7A2-2
General Description ...............................................
7A2-2
Electronic Control Diagram ...............................
7A2-3
Transmission Control Module (TCM) (1/2) ......
7A2-4
Transmission Control Module (TCM) (2/2) ......
7A2-5
TCM Point Table .................................................
7A2-6
TCM Voltage & Resistance Check Sheet .......
7A2-7
Control System Diagram ....................................
7A2-9
Control and Functions ........................................
7A2-10
Gear Shift Control 3rd start ...............................
7A2-10
Mode Type ...........................................................
7A2-10
Mode Selection ....................................................
7A2-10
Comparison of mode ..........................................
7A2-11
3rd start Mode .....................................................
7A2-11
Backup Mode .......................................................
7A2-11
Functions of Input / Output Components ........
7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................
7A2-13
High speed CAN bus ..........................................
7A2-13
Diagnosis .................................................................
7A2-13
Electronic Diagnosis ...........................................
7A2-13
Check Trans Indicator ........................................
7A2-13
On Board Diagnostic Check ..............................
7A2-13
"Check Trans" Check .........................................
7A2-14
Tech 2 OBD Connection ....................................
7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............
7A2-30
16 - Terminal Data Link Connector (DLC) ......
7A2-31
Clear DTC ............................................................
7A2-32
DTC Check ..........................................................
7A2-32
TCM Precaution ..................................................
7A2-32
Information On TCM ...........................................
7A2-32
TCM Diagnostic Trouble Codes ........................
7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ...........................................
7A2-34

DTC P0602 (FLASHING CODE 63)
Transmission Control Module (TCM)
Programming Error ................................................
7A2-36
DTC P0705 (FLASHING CODE 17)
Transmission Range Sensor Circuit
Malfunction .............................................................
7A2-38
DTC P0712 (FLASHING CODE 15)
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................
7A2-42
DTC P0713 (FLASHING CODE 16)
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................
7A2-45
DTC P0717 (FLASHING CODE 14)
Input Speed Sensor Signal Error .........................
7A2-48
DTC P0722 (FLASHING CODE 11)
Output Speed Sensor Signal Error .....................
7A2-51
DTC P0743 (FLASHING CODE 33)
Torque Converter Clutch Electrical .....................
7A2-54
DTC P0748 (FLASHING CODE 35)
Pressure Control Solenoid Electrical ..................
7A2-57
DTC P0753 (FLASHING CODE 31)
Shift Solenoid S1 Electrical ..................................
7A2-60
DTC P0758 (FLASHING CODE 32)
Shift Solenoid S2 Electrical ..................................
7A2-63
DTC P1767 (FLASHING CODE 67)
ECM CAN Invalid ...................................................
7A2-66
DTC P1790 (FLASHING CODE 61)
Transmission Control Module ROM
Checksum Error .....................................................
7A2-69
DTC P1791 (FLASHING CODE 62)
Transmission Control Module RAM
Error .........................................................................
7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................
7A2-73

7A2-2 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
General Description
The AW30-40LE is a 4–speed fully automatic
transmission. It uses a microcomputer as a control unit
to judge running conditions including throttle opening
rate and vehicle speed, then it sets the shifting point in
the optimum timing so that best driving performance
can be achieved.
In addition, the built–in shift mode select function can
select three shift modes according to the driver's
preference:
 Normal mode –Normal shift pattern.
 3rd Start mode –Starts in 3rd gear to reduce
slippage on ice or snow.
 Power mode has a delayed up shift when more
powerful acceleration is required.
Also, the built–in fail–safe function (“backup mode")
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the self–diagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of AW30-40LE are as follows:

A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
 Electronic control selects the optimum shift mode according to the driving conditions.
 Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
 Two sets of planetary gears reduce friction of powe
r
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.
 Wide gear ratio and high torque rate of torque
converter provide excellent starting performance.