2004 ISUZU TF SERIES engine oil

7D-4 TRANSFER CASE

Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
220R300018
Legend


(1) Rear Propeller Shaft

(2) Oil Seal


Removal
1.
Disconnect the rear propeller shaft (1) from the
transfer case side.
2.
Remove the oil seal from the transfer case.

Installation
1.
Install oil seal and apply engine oil to the oil seal
outer surfaces.
2.
Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3.
Use the oil seal installer 5-8840-2786-0 to install the
rear seal (2) to the transfer rear case.

TRANSFER CASE 7D-11

Transfer Disassembly

RTW47DLF000101
Legend


(7) Neutral Switch ASM
(1) Transfer Case

(8) Speedometer Bush, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut

(9)Transfer Actuator
(3) Stoneguard

(10)Breather Hose
(4) Detent Plug, Spring and Detent Ball

(11) Heat Protector (Except Diesel Engine)
(5) 2-4 Switch ASM


(6) Switch Bracket



Removal
1.
Remove the stoneguard.
2.
Remove the drain plug from the transfer case to
drain the oil.
3.
Remove the parts listed below.


Speedometer bush, plate, and speedomete
r
driven gear


Breather hose (Between the transfer case and
the transfer actuator assembly)


Transfer actuator assembly


Switch bracket

TRANSFER CASE 7D-31

226R300011
36.
Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 Nm (2.2 kgm/16 lbft)
37.
Apply engine oil to the companion flange O-ring.
38.
Install the O-ring to the front output shaft.
39.
Secure the front companion flange with the
companion flange holder (5-8840-0133-0).
40.
Install the end nuts and tighten them to the specified
torque.

Front companion flange end nut torque:
137 Nm (14 kgm/101 lbft)












41.
Use a cold chisel to caulk the front companion
flange end nuts.
226R300012
RUW34DSH000301

Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)

42.
Apply Loctite 575 to the threaded portion of the
detenteplugs.

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

TCM Voltage & Resistance Check Sheet
CHECK ITEM PIN No. VALUE NOTE
VIGN A6 –A1 VIGN
Key “ON ”

A6 –A23 VIGN
Key “ON ”
Backup Power Supply A24 –A1 +B (Always)
Key “ON ”
Inhibitor (Select) SW P B20 –A1 “P ” Range VIGN Key “ON ”

Except “P ” 0V
Inhibitor (Select) SW R B1
–A1 “R ” Range VIGN Key “ON ”

Except “R ” 0V
Inhibitor (Select) SW N B8
–A1 “N ” Range VIGN Key “ON ”

Except “N ” 0V
Inhibitor (Select) SW D B7
–A1 “D ” Range VIGN Key “ON ”

Except “D ” 0V
Inhibitor (Select) SW 2 B19
–A1 “2 ” Range VIGN Key “ON ”

Except “2 ” 0V
Inhibitor (Select)SW 1 B18
–A1 “1 ” Range VIGN Key “ON ”

Except “1 ” 0V
Inhibitor (Select) SW 3 B9
–A1 “3 ” Range VIGN Key “ON ”

Except “3 ” 0V
Power SW B13
–A1 ON 0V Key “ON ”

OFF VIGN
3rd Start SW B4
–A1 ON 0V Key “ON ”

OFF VIGN
Brake SW B22
–A1 ON VIGN Key “ON ”

OFF 0V
AT Oil Temperature
Sensor A11
–A12 20
C 4.6V Engine run.

155

C 1.1V
4L Signal B21
–A1 4L 0V Key “ON ”

2H/4H VIGN
Diag SW B12
–A1 ON VIGN Key “ON ”

OFF 0V
Shift Solenoid A (S1) A16
–A1 P VIGN Engine run.

R VIGN

N VIGN

D –1 VIGN

D –2 VIGN

D –3 0V

D –4 0V

7A2-8 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

CHECK ITEM PIN No. VALUE NOTE
Shift Solenoid B (S2) A15 –A1 P 0V Engine run.

R 0V Engine run. (Without the
Reverse range lock out)
N 0V Engine run.
D –1 0V

D –2 VIGN

D –3 VIGN

D –4 0V
Lock-up Solenoid A5
–A1 ON VIGN (ex.) It is “ON ” when the
vehicle speed is more than
65km/h.
OFF 0V
Check Trans Lamp B3
–A1 ON 0V Key “ON ”
(The lamp is “ON ” for 3
second after key “ON ”)

OFF VIGN
AT Oil Temperature Lamp B11
–A1 ON 0V Key “ON ”
(The lamp is “ON ” for 3
second after key “ON ”)

OFF VIGN
Power Lamp B2
–A1 ON 0V Key “ON ”
(The lamp is “ON ” when the
Power switch is “ON ”)

OFF VIGN
3 rd Start Lamp B10
–A1 ON 0V Key “ON ”
(The lamp is “ON ” when the
3rd Start switch is “ON ”)

OFF VIGN
AT Oil Temp Sensor
Resistance A11
–A12 20

C
12k
Key “OFF ”

50

C 1.5k

155

C 293

Pressure Control Solenoid
Resistance A4
–A2 About
4 –7

(20

C)
Key “OFF ”
Speed Sensor Resistance B5 –B14 About
560

– 120
(20

C)
Key “OFF ”
Input Revolution Sensor
Resistance B6
–B16 About
560

– 120
(20

C)
Key “OFF ”
Lock-up Solenoid
Resistance A5
–A1 About
10

– 15
(20

C)
Key “OFF ”
Shift Solenoid A (S1)
Resistance A16
–A1 About
10

– 15
(20
C)
Key “OFF ”
Shift Solenoid B (S2)
Resistance A15
–A1 About
10

– 15
(20

C)
Key “OFF ”

7A2-10 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Control and Functions
Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the
gear ratio is controlled by the ON/ OFF signal using the
shift solenoid S1 and the shift solenoid S2.
Band Apply Control
The band apply is controlled when in the 3 –2 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow
of the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch (TCC) solenoid using the ON/OFF
signal.
Line Pressure Control
The throttle signal allows the current signal to be sent
to the force motor. After receiving the current signal,
the force motor activates the pressure regulator valve
to regulate the line pressure.
On –Board Diagnostic System
Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and read
out of it afterward.
The serial data lines, which are required for the testing
of the final assembly and the coupling to othe
r
electronic modules, can be regulated by this function.
Fail –Safe Mechanism
If there is a problem in the transmission system, the
TCM will go into a “backup" mode.
The vehicle can still be driven, but the driver must use
the select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change o
f
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning,
TCC, and the 3rd start mode.
Reverse Lock Out Control
With the selector lever in reverse position, the TCM will
not close the PWM solenoid until the vehicle is below
15 km/h (9.3 mph), thus preventing reverse
engagement above this speed.

Downhill Control
This mode is automatically activated from NORMAL
mode only when downhill conditions are recognized.
The shift pattern is identical to NORMAL mode except
3-4 and 4-3 shift lines at low throttle modified to get
engine braking on a larger speed range.
Uphill Control
When uphill condition are recognized the 2-3 and 3-4
shift and TCC apply are down only when the engine
torque is sufficient in order to avoid shift hunting.
Gear Shift Control 3rd start


SELECT LEVER RANGE SHIFT PATTERN
D(Drive) 1


2TCC

3TCC

4TCC
3(Third) 1

2TCC

3TCC
2(Second) 1

2(
3)
L(First) 1(
2)
TCC: Torque Converter Clutch
(Notice1): “( )" means over-revving prevention control.
Mode Type


Mode Type Select lever position
Normal drive mode
(NOR) Entire range (excluding “R")
Power drive mode
(PWR) Entire range (excluding “R")

Mode Selection



SWITCH(SW) LAMP
Mode Type PWR/N
OR.S 3RD
START SW POWER
DRIVE LAMP 3RD
START LAMP
Normal
drive mode
(NOR) OFF OFF OFF OFF
Power
drive mod
(PWR) ON OFF ON OFF
3rd Start
mode OFF ON OFF ON
However, the 3rd start switch prevails over the
PWR/NOR switch.
The mode become normal drive mode when the 3rd
start switch is operated from ON to OFF.

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.




I
n
p
u t
Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.
I
n
p
u t
/
O
u t
p
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.



O
u
t
p
u
t
3rd Start lamp Lights when 3rd Start MODE detected.
C
o
m
p
u t
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