2004 ISUZU TF SERIES fuel

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.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-37

DTC P0602 (FLASHING CODE 63) Transmission Control Module (TCM)
Programming Error
Circuit Description
The Service Programming System (SPS) updates the
flash calibration files that are stored in a Transmission
Control Module (TCM). The calibration file
custom-tailors a module to a certain vehicle. The
calibration file contains data for things such as spark
curves and fuel control. When troubleshooting a
driveability problem, diagnosis may call fo
r
reprogramming the controller with newer calibration
information to correct a customer concern and Vehicle
Identification Number (VIN).
Condition for setting the DTC
When the TCM is not written VIN No.
Action Taken When The DTC Sets

DTC stored.
Conditions For Clearing The DTC

The DTC can be cleared from the TCM history by
using a scan tool.
 The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.

After more than 1 second has elapsed after the
ignition key has been turned “ON", short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
DTC P0602 is indicated when the TCM does not written
VIN No. A security lock is performed by SPS. And not
replace the TCM when DTC P0602 can repair by SPS.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-55

DTC P0743 (FLASHING CODE 33) Torque Converter Clutch Electrical


RUW37ALF000601
Circuit Description
The lock-up solenoid SL of the torque converter clutch
(TCC) controls the lock-up clutch by a signal according
to the lock-up range judgment of the TCM when the
vehicle runs.
This function can improve the fuel consumption to
almost the same extent as the manual transmission.
The lock-up solenoid SL is put into B+ by the TCM, so
that the solenoid is actuated with the result of lock-up.
Condition for setting the DTC
The TCM detects following conditions both "Condition
1" and "Condition 2" occur 2 times or more than it.
Condition 1 ("GND short"):

Voltage at connector pin is 0V for 0.3 sec
continuously when solenoid is “ON".
Condition 2 ("Open or IG short"):

Voltage at connector pin is ignition voltage for 0.5
sec continuously when solenoid is “OFF".
Action Taken When The DTC Sets

No lock-up control.
 The TCM fixes to 1st gear when the vehicle speed is
less than 6 mph.

Check Trans ON.

DTC stored.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-35

Shift Solenoid and Lock-Up Solenoid
Removal
Preparation:

Disconnect negative ( –) battery cable.
 Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove oil lever gage and oil filler tube.
2. Support transfer case (4
4) or rear cover (42)
with a transmission jack.
3. Remove engine rear mounting nuts.


F07RW008
4. Remove fule pipe heat protector on tansmission
corssmenber.
5. Remove fuel pipe from the crossmenber.
6. Remove transmission crossmenber.
7. Remove the nineteen bolts.
8. Remove oil pan, using seal cutter J –37228.



RUW37ASH002901

NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J –37228
Examine particles in oil pan
Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type o
f
wear you will find in the transmission:
Steel (magnetic) ..................bearing, gear and
clutch plate wear
Brass (non-magnetic) ..........bushing wear



240RY00008
9. Remove the oil strainer assembly.



244RY00003

7A3-42 ON-VEHICLE SERVICE (AW30 –40LE)

Transmission Assembly
Transmission and Associated Parts




Legend
(9) Under Cover
(1) Rear Propeller Shaft (10) Flex Plate Torque Converter bolt
(2) Front Propeller Shaft (4WD only) (11) Shift Cable
(3) Middle Exhaust Pipe (12) Rear Mount Rubber
(4) Transfer Case Assembly (4WD only) (13) Heat Protector
(5) Fuel Pipe Clip and Bracket (14) Transmission Crossmember
(6) ATF Pipe and Clip (15) Transmission Assembly (2WD)
(7) Oil Level Gauge and Guide Tube (16) Transmission Assembly (4WD)
(8) Suspension Crossmember

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-43

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands.
3. Remove front propeller shaft.(4WD only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
5. Remove the middle exhaust pipe.



RTW37ASH0001

6. Disconnect the transfer harness connectors and the
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
7. Support transfer case with a transmission jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.






P1010010
11. Discinnect the transmission harness connectors
and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.

7A3-44 ON-VEHICLE SERVICE (AW30 –40LE)

14. Remove the under covers.





P1010012
15. Remove the flex plate torque converter bolts by
turning the crank shaft.





P1010005

16. Remove the heat protector and the fuel pipe clips
with fuel pipes on the transmission crossmember.





P1010005B
17.Disconnect the ATF pipes.
18. Remove the ATF pipe clips.




P1010024

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-45

19.Support the transmission with a transmission jack.



220RS0001
20.Remove the transmission crossmember.

Remove engine rear mount nuts fixing on
transmission crossmember.





P1010018

Remove the transmission crossmember by
removing four fixing bolts.
 If necessary, remove the rear mount rubber from
the transmission.
21. Disconnect the air bleezer hose at the transmission.

22.Remove the protector and fuel pipe bracket.

Loosen the nut (1) and remove the protector (2).
 Remove the bracket with the fuel pipes (3) and
put aside it.



RTW37ASH001201
23.Remove the transmission assembly.

Remove transmission retaining nuts and bolts.
 Remove transmission assembly from the vehicle.