2004 ISUZU TF SERIES torque

7A3-2 ON-VEHICLE SERVICE (AW30 –40LE)

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.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-13

Measure Stall Speed
1. Chock the four wheels.
2. Mount an engine tachometer.
3. Fully apply the parking brake.
4. Step down strongly on the brake pedal with your left foot.
5. Start the engine.
6. Turn off the A/C.
7. Shift into the “D" range. Step all the way down on
the accelerator pedal with your right foot. Quickl
y
read the highest engine rpm.
Stall speed: 2100






150 rpm
8. Perform the same test in the “R" range.
Evaluation

1. If the engine speed is the same for both ranges but
lower than the specified value:
 Engine output is insufficient.
 Stator one-way clutch is not operating properly.
NOTE: If more than 600 rpm below the specified value,
the torque converter could be faulty.
2. If the stall speed in “D" range is higher than
specified:
 Line pressure too low
 Forward clutch slipping
 No.2 one-way clutch not operating properly
3. If the stall speed in “R" range is higher than
specified:
 Line pressure too low
 Direct clutch slipping
 No.3 brake slipping
4. If the stall speed in the “R" and “D" ranges are
higher than specified:
 Line pressure too low
 Improper fluid level

Time Lag Test



F07RY00003
If the shift lever is shifted while the engine is idling,
there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the forward clutch, direct clutch, No.3
brake, and No.2 one-way clutch.
NOTE:
1. Perform the test at normal operation fluid
temperature (50 – 80 C or 122 – 176 F)
2. Be sure to allow one minute interval between tests.
3. Make three measurements and take the average value.

7A3-16 ON-VEHICLE SERVICE (AW30 –40LE)

Evaluation
i. If there is no 1 
2 upshift:

Solenoid S2 is stuck
 1 –2 shift valve is stuck
ii. If there is no 2 
3 upshift:

Solenoid S1 is stuck
 2 –3 shift valve is stuck
iii. If there is no 3 
OD upshift (throttle valve opening
1/2):

Solenoid S2 is stuck
 3 –OD shift valve is stuck
iv. If the shift point is defective: Refer to TROUBLESHOOTING CHART in this
section.
v. If the lock-up is defective: Refer to TROUBLESHOOTING CHART in this
section.
2. In the same manner, check the shock and slip at the 1 
2, 2 
3 and 3 
OD upshifts.
NOTE: Drive the vehicle on level ground.
Evaluation
If the shock is excessive:
Refer to TROUBLESHOOTING CHART in this section.
3. Run at “D" range lock-up or OD gear and check fo
r
abnormal noise and vibration.
NOTE: The check for the cause of abnormal noise and
vibration must be made with extreme care as it could
also be due to loss of balance in the propeller shaft,
differential, the torque converter, etc. or insufficient
bending, rigidity, etc. in the power train.



RUW37ASH000201

4. While running in “D" range, 2nd, 3rd gears and OD,
check to see that the possible kick-down vehicle
speed limits for 2 1, 3 1, 3 2, OD 3 and
OD 
2 kick-downs conform to those indicated on
the automatic shift diagram.



RUW37AMH000101
5. Check for abnormal shock and slip at kick-down.
6. While running in “D" range, OD gear or “lock-up",
shift to “2" and “L" ranges and check the engine
braking effect at each of these ranges.
7. Also check to see that downshift is made from 3 
2
or from OD to 3 and then to 2 immediately and that
2 
1 downshift point is within the limits shown in the
diagram when tested by releasing the accelerato
r
pedal and shifting into position of “L" while driving in
the third gear or in overdrive.

7A3-22 ON-VEHICLE SERVICE (AW30 –40LE)

ATF Replacement
Inspection
NOTE: Do not overfill.
1. Remove the drain plug from oil pan and drain the
fluid.




RUW17ASH013401
2. Reinstall the drain plug securely.
Torque: 19 N 


m (14 Ib ft)
3. With the engine OFF, add new fluid through the fille
r
tube.



Drain and refill 5.2 liter
Dry fill 8.7 liter
Fluid BESCO ATF III
4. Start the engine and shift the selector into all
position from “P" through “L", and then shift into “P".
5. With the engine idling, check the fluid level. Add fluid up to the “COLD" level on the dipstick.
6. The ATF level must be checked again for correct level with the “HOT" level.
NOTE: To prevent fluid leaks, the drain plug gasket
must be replaced each time this plug is removed.

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-23

Neutral Start Switch (Mode Switch)
Inspection
With a circuit tester, make a continuity test on the
neutral start switch with the moving piece set in each
position.










RTW37BSH000101
Removal
Preparation:
Disconnect negative ( –) battery cable.
1. Remove the rear side ATF cooler pipe from the
transmission elbow.
2. Disconnect neutral start switch connector.
3. Unstake the lock washer, and then remove the shaft
nut.
4. Remove the neutral start switch.
Installation
To install, follow the removal steps in the reverse order,
noting the following points;
If a engine starts at any selector position except “N ” o
r
“ P ”, the neutral start switch (mode switch) should be
adjusted.
1. Loosen the neutral start switch bolt and set the shift
selector to the “N" range.
2. Align the groove and neutral basic line.
3. Hold in position and tighten the bolt and nut.
Torque:
Nut – 7 N 


m (61 Ib in)
Bolt – 13 N 


m (113 Ib in)
4. Lock the nut with the lock washer tubs at two points.



RUW17ASH013601

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-27

ATF Temperature Sensor
Inspection

1. Disconnect the front side ATF cooler pipe from the
elbow and remove the elbow.
2. Remove the ATF temperature sensor from the transmission case.
3. Place the ATF temperature sensor in a container o
f
ATF.



RUW37ASH004001
4. Measure the resistance between each terminals,
while warming ATF.
Resistance: 0.5 – 30 k






(at 0

 

C – 120 
 

C)
5. If either of the measured values exceeds the
specified value, replace the ATF temperature
sensor.
Torque: 15 N 


m (11 Ib ft)

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-29

8.
Remove the upper housing (held in place by 4
latched fasteners).
9.
Remove the spring plate.
10.
Remove the grooved pin.
11.
Remove the lever assembly by pressing the rod
down (lever in N position).
12.
If lamp replacement is required, remove the lamp
assembly from the lamp socket (align the socke
t
grooved portion and the lamp assembly protruding
portion).

Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.
RTW37ALH000201

1.
Install the lever assembly to the base plate.
a.
Insert and secure shaft.
b.
Insert paw led end of shaft into base plate hole.
c.
Insert grooved pin of shaft into detente aperture
(lever assembly in N position).
2.Install the spring plate. a.
Insert the grooved pin into the base plate detente
groove until it touches the front wall (leve
r
assembly in N position).
RTW37ASH001001
b.
Install the spring plate tighten the screws to the
specified torque.


Screw torque 2 N

m (0.2 kg

m/17 lb in)
c.
Check that the grooved pin moves smoothly in
the detente groove (shift knob temporaril
y
installed).
3.
Temporarily install the sleeve.
4.
Install the lamp assembly to the lamp socket (i
f
removed at disassembly).
a.
Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b.
Insert the lamp assembly into the lamp socket
and rotate it 90 degrees clockwise.
5.
Attach the harness connectors to the base plate.
6.
Move the lever to the “P ” position.
7.
Install the sleeve (rotate the sleeve clockwise the
same number of turns it was rotated
counterclockwise at disassembly).
8.
Install the knob, the knob button, and the knob
spring.

7A3-30 ON-VEHICLE SERVICE (AW30 –40LE)

9.
Adjust the clearance (2) between the detente plate
and the pin by moving the select lever knob sleeve
(1).
Detente plate and pin clearance
mm(in
)
0.2 - 1.0 (0.01 - 0.04)

255R300002
10.
Install the 2 screws securing the knob and tighten
them to the specified torque.
Screw torque: 2 N 
m (0.2kg 
m/17 lb in)
11.
Install the upper housing. Make sure that the 4
latched fasteners are securely closed.