2004 ISUZU TF SERIES transmission fluid

7A2-6 DIAGNOSIS (JR405E)
BASIC TROUBLE SHOOTING

Transmission fluid pressure together with clutch and brake friction and other important transmission functions are
controlled by electrical signal from the Transmission Control Module (TCM).
Random diagnosis can produce inaccurate and misleading indications. It is important that diagnosing procedure be
carried out systematically.
Carefully follow the sequence outlined below to diagnose automatic transmission assembly.




Verify Customer Complain
Preliminary Check
(Visual Check/Test Drive)
Compare to Same Model
(If Available)
Check Service Bulletin
DTC Check
(Self-diagnosis/Tech 2)
Go to Symptom Diagnosis
Stall Test
Line Pressure Test
Transmission Overhaul
Repair & Verify Fix
Transmission Overhaul
Transmission Overhaul
Go to DTC Chart
Go to Intermittent Diagnosis NG
Follow the instructions
NG
No Instruction
NG
OK
NO DTC
Not Solved
OK
OK
Follow the Bulletin
(Once Clear Memory) Restored
Not Stored
Use Service Programming
System (SPS)
Not Solved

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20

7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.



AUTOMATIC TRANSMISSION FLUID (ATF)
Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch band
and other parts.
The transmission control module, the transmission unit,
and the vehicle must be carefully checked if gum or
varnish is present.




ATF LEVEL
Inspect
Hot Level
1. Warm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80
C (176
F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each gear range just long enough for the
transmission to engage.
5. Return the select lever to either “P” or “N”.
C07RW009
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.
9. Remove the dipstick.
The ATF level should be inside the “H” range on the
dipstick.
242R300001
If the ATF level is below the “H” range, ATF must be
added.

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.

Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil
Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (69 lb·in)
6. Fill the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. When the abnormal amount of debris are found.
2. When the abnormal wear or chips on gears and
shafts are found while overhauling.
3. When the abnormal clutch facing wear and oil
contamination are found.

Procedures
1. Block the wheels.
2. Disconnect negative battery cable.
3. Raise vehicle and support with suitable safety
stands.
4. Disconnect fluid cooler lines at transmission case
and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using
solvent and compressed air.
Note:
DO NOT exceed 197 kPa (29 psi) air pressure or
damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic
Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (33 lb·ft)
8. Replenish ATF
9. Start engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all
debris from the fluid cooler circuit.
Move the select lever through the various ranges and
return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF
must be added.
10. Connect negative battery cable.
11. Remove safety stands.
12. Remove wheel blocks.

ON-VEHICLE SERVICE (JR405E) 7A3-21
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.
6. Loosen (do not remove) the nuts securing the
exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the
transmission.
8. Remove the fuel pipe bracket.
P1010013

P1010014
9. Remove the ATF level dipstick and tube.
10. Remove the undercover.
11. Rotate the ring gear and remove the 6 torque
converter bolts.
P1010016
12. Remove the automatic transmission fluid cooling
pipe.
P1010060
13. Place a jack beneath the engine to support it.
14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the
engine and transmission. Do not allow the radiato
r
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the
engine.
18. Lower the transmission from beneath the vehicle.
Take care not to damage the breathers.

Install or Connect
1. Install the transmission to the engine and tighten the
bolts.
Bolt torque : M10 40 N·m (30 lb·ft)
M12 76 N·m (56 lb·ft)
2. Install the cable bracket to the transmission.
3. Connect the engine harness connectors.

7A3-22 ON-VEHICLE SERVICE (JR405E)

4. Install the 3rd crossmember.
Bolt and Nut torque : 67 N·m (49 lb·ft)
Bolt torque : 50 N·m (37 lb·ft)
5. Install the automatic transmission fluid cooling pipe.
6. Install the torque converter bolts.
Bolt torque : 29 N·m (22 lb·ft)
7. Install the undercover.
Bolt torque : 9 N·m (78 lb·in)
8. Install the ATF level dipstick and tube.
9. Install the fuel hose bracket.
Bolt torque : 6 N·m (52 lb·in)

10. Tighten the nuts securing the exhaust manifold and
the exhaust pipe.
Bolt torque : 43 N·m (32 lb·ft)
11. Install the rear propeller shaft assembly.
Flange bolt torque : 63 N·m (46 lb·ft)
Center bearing bracket bolt torque :
69 N·m (51 lb·ft)
12. Install the shift cable.
13. Connect the negative battery cable.
14. Remove the safety stands.
15. Remove the wheels blocks.


Torque Specifications
RTW37ALF001501

UNIT REPAIR (JR405E) 7A4-3
Disassembly steps
1. Torque converter

Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.

Draining the ATF from the torque converter.


01ASSY101

2. Turbine sensor and speed sensor

Remove the turbine sensor from the transmission case.



02ASSY103



Remove the speed sensor from the transmission case.



03ASSY106

3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.


240L300002

4. Oil pan

Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0

Remove the drain plug from the oil pan and drain the
ATF from the oil pan.

Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.

Rotate the automatic transmission so that the oil pan is
facing up.

Remove the 19 bolts and the oil pan.

UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43



Use a pin punch to drive the manual plate spring pin into
place.


21CASE-AY48

3. Detent spring

Install the detent spring and tighten the fixing bolt to the
specified torque.
Torque: 7 N






m (61 Ib






in)


23CASE-AY53

4. Harness assembly

Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.

Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
Torque: 6 N






m (52 Ib






in)


24ASSY003

5. Low one-way clutch inner race

Install new seal rings to the low one-way clutch inne
r
race.


25ASSY126



Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0004~0.001 in)