2004 ISUZU TF SERIES service

MANUAL TRANSMISSION 7B1-1

SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (4





2)
Service Precaution .......................................................................................................... 7B1 – 3
General Description ........................................................................................................ 7B1 – 4
Rear Oil Seal (4




2) ........................................................................................................... 7B1 – 5
Transmission (4




2) ......................................................................................................... 7B1 – 7
Disassembled View ..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –12
Transmission Case .......................................................................................................... 7B1 –18
Major Component ........................................................................................................ 7B1 –18
Disassembly ................................................................................................................ 7B1 –19
Reassembly ................................................................................................................. 7B1 –20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –23
Disassembled View ..................................................................................................... 7B1 –23
Disassembly ................................................................................................................ 7B1 –24
Inspection and Repair ................................................................................................. 7B1 –25
Reassembly ................................................................................................................. 7B1 –26
Reverse Gear and 5th Gear ............................................................................................ 7B1 –27
Disassembled View ..................................................................................................... 7B1 –27
Disassembly ................................................................................................................ 7B1 –29
Inspection and Repair ................................................................................................. 7B1 –31
Reassembly ................................................................................................................. 7B1 –31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –38
Disassembled View ..................................................................................................... 7B1 –38
Disassembly ................................................................................................................ 7B1 –40
Inspection and Repair ................................................................................................. 7B1 –42
Reassembly ................................................................................................................. 7B1 –45
Main Data and Specifications ......................................................................................... 7B1 –51

7B1-2 MANUAL TRANSMISSION

Troubleshooting ............................................................................................................... 7B1 –55
Special Tools (4





2) .......................................................................................................... 7B1 –62


MUA (4





4)
Service Precaution .......................................................................................................... 7B1 –63
General Description ........................................................................................................ 7B1 –64
Transmission (4




4) ......................................................................................................... 7B1 –65
Disassembled View ..................................................................................................... 7B1 –65
Removal ....................................................................................................................... 7B1 –66
Installation ................................................................................................................... 7B1 –70
Transmission Case .......................................................................................................... 7B1 –77
Major Component ........................................................................................................ 7B1 –77
Disassembly ................................................................................................................ 7B1 –78
Reassembly ................................................................................................................. 7B1 –79
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –82
Disassembled View ..................................................................................................... 7B1 –82
Disassembly ................................................................................................................ 7B1 –83
Inspection and Repair ................................................................................................. 7B1 –83
Reassembly ................................................................................................................. 7B1 –84
Reverse Gear and 5th Gear ............................................................................................ 7B1 –85
Disassembled View ..................................................................................................... 7B1 –85
Disassembly ................................................................................................................ 7B1 –86
Inspection and Repair ................................................................................................. 7B1 –88
Reassembly ................................................................................................................. 7B1 –88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –94
Disassembled View ..................................................................................................... 7B1 –94
Disassembly ................................................................................................................ 7B1 –96
Inspection and Repair .............................................................................................. 7B1 – 98
Reassembly .............................................................................................................. 7B1 – 101
Main Data and Specifications ..................................................................................... 7B1 – 107
Troubleshooting ........................................................................................................... 7B1 – 111
Special Tools (4





4) ...................................................................................................... 7B1 – 118

MANUAL TRANSMISSION 7B1-3

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, REFER
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, or
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.

7B1-62 MANUAL TRANSMISSION

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, REFER
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, or
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.

IMMOBILIZER SYSTEM 11A-1

SECTION 11A
IMMOBILIZER SYSTEM
CONTENTS

Service Precaution.................................................
11A-2
General Description...............................................
11A-3
What happens without proper transponder
operation? ..........................................................
11A-6
No proper transponder is available, what
should be done for the system? ......................
11A-6
Caution to the operation.....................................
11A-6
Summary of operation........................................
11A-6
What your organization should provide for
your customer ....................................................
11A-6
Car Pass .............................................................
11A-6
Security code management ..............................
11A-6
Essential tool (Scan tool : Tech-2) ..................
11A-6
Circuit Diagram .................................................
11A-7
Parts Location.........................................................
11A-10
Immobilizer control unit (ICU); For Electronic
Control Engine (6VE1, C24SE, 4JH1-TC,
4JA1-TC) .......................................................... 11A-11
Pin-outs; For Electronic Control Engine
(6VE1, C24SE, 4JH1-TC, 4JA1-TC)...............
11A-12
Immobilizer control unit (ICU); Mechanical
Control Engine (4JA1-T) .................................. 11A-13
Immobilizer coil (Antenna) ...................................
11A-15
Transponder (Key) ............................................ 11A-15
Immobilizer warning lamp ................................. 11A-15
Engine control module (ECM) .......................... 11A-15
Car Pass Card .................................................. 11A-16
Loss of car pass card.........................................
11A-16
Instructions on Filling Out the form "Data
request, car pass" .............................................
11A-16
Important Instructions ........................................
11A-17
lmportant information on Programming .............
11A-19
Security code ......................................................
11A-19
Entering a code ..................................................
11A-19
Transponder (Key) .............................................
11A-19
Important .............................................................
11A-19
Tech-2 Scan Tool ..................................................
11A-20
Tech-2 Features .................................................
11A-21
Getting Started ...................................................
11A-21
Operating Procedure .........................................
11A-22
Menu ....................................................................
11A-23
DTC ......................................................................
11A-23
Clear DTC Information .......................................
11A-23
Tech-2 Data Display ...........................................
11A-23
Check Vehicle Identification Number (VIN) ....
11A-23
Reset Immobilizer (Reset Immobilizer
Control Unit) .......................................................
11A-23
Reset Engine Control Module (Reset ECM) ...
11A-24
Erase transponder key .......................................
11A-24
Programming Immobilizer Function .................
11A-25
Programming ICU ...............................................
11A-26
Programming ECM .............................................
11A-27
Programming ICU and ECM .............................
11A-28
Transponder program ........................................
11A-28
Data List ...............................................................
11A-30
Diagnostic procedure ............................................
11A-31
Clearing Diagnostic Trouble Codes ....................
11A-31
Verifying Vehicle Repair ........................................
11A-31
Diagnostic Aids ......................................................
11A-31
Check the condition for system parts ..............
11A-31
Check the Electro-Magnetic Interference
(EMI) ....................................................................
11A-31
Check the other items ........................................
11A-31
Check the operation ...........................................
11A-31
Diagnostic Trouble Code (DTC) list ....................
11A-32
IMMOBILIZER SYSTEM CHECK ........................
11A-33
NO IMMOBILIZER WARNING LAMP .................
11A-36
IMMOBILIZER WARNING LAMP ON STEADY 11A-37
B0001 REPLACE ELECTRONIC CONTROL
UNIT (ECU) (IMMOBILIZER FAULT) ................
11A-38
B0002 IMMOBILIZER NOT PROGRAMMED ....
11A-39
B0003 TRANSPONDER KEY PROBLEM ..........
11A-40
B0004 IMMOBILIZER COIL CIRCUIT
(ANTENNA COIL FAULT) ...................................
11A-42
B0005 COMMUNICATION LINE W VOLTAGE
LOW .......................................................................
11A-43
B0006 COMMUNICATION LINE W VOLTAGE
HIGH .......................................................................
11A-44
B0007 NO ENGINE REQUEST RECEIVED ......
11A-45
B0008 WRONG TRANSPONDER KEY .............
11A-47
B0009 NO TRANSPONDER KEY
PROGRAMMED ...................................................
11A-48

11A-2 IMMOBILIZER SYSTEM

B0010 UNKNOWN TRANSPONDER KEY .......
11A-49
B0011 TRANSPONDER KEY PROBLEM
(Only 4JA1-T Engine) ...................................... 11A-50
B0012 WRONG TRANSPONDER KEY
(Only 4JA1-T Engine) ...................................... 11A-52
B0013 IMMOBILIZER NOT PROGRAMMED
(Only 4JA1-T Engine) ...................................... 11A-53
B0014 NO TRANSPONDER KEY
PROGRAMMED (Only 4JA1-T Engine) ........... 11A-54
B0015 VEHICLE SPEED SIGNAL LOW
(Only 4JA1-T Engine) ....................................... 11A-55
B0016 VEHICLE SPEED SIGNAL HIGH
(Only 4JA1-T Engine) ...................................... 11A-56
B0023 IMMOBILIZER COIL CIRCUIT
(ANTENNA COIL FAULT)
(Only 4JA1-T Engine) ...................................... 11A-57
B0024 WRONG TRANSPONDER KEY
(Only 4JA1-T Engne) ....................................... 11A-58
B0055 EEPROM ERROR ................................. 11A-59
Special Tool ............................................................
11A-60

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 o
r
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.

IMMOBILIZER SYSTEM 11A-17

Important Instructions
Only data corresponding to the delivery status of the
vehicle can be issued. Car pass data requests will onl
y
be processed if the first column is filled out completely.
Signed and sent to your organization along with proof of
ownership.
Information via telephone is only possible in exceptional
circumstances via your service organization.
As for the delivery of new vehicles, the customer must
be informed about all features of the car pass that are
relevant to vehicle security, for example, that the ca
r
pass should be kept in a safe place(not in the vehicle)
and should be presented when an authorized you
r
organization name workshop is visited, The exact
phrasing can be found in the relevant Owner's Manual.

11A-20 IMMOBILIZER SYSTEM

Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.




LTW3BALF000501-X

Legend

(1) PCMCIA Card

(2)
SAE 16/19 Adaptor

(3)
DLC Cable


(4)
Tech-2

(5)
RS232C Cable