2004 ISUZU TF SERIES section 1A

3E-10 WHEELS AND TIRES

TROUBLESHOOTING
Typical examples of abnormal tire tread wear and major causes :

CAUTION:
Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and
other suspension related problems.


Spotty wear - wear localized
on shoulder section. In
extreme cases, the tire
becomes polygonal in shape.
Tire or wheel out of
round or distorted.Hub or knuckle out
of round or distorted.Play in hub bearings
or ball joints.Rotating parts out of
balance.
Tread wear one-sided.
Rotating parts out of
balance.Tire or wheel out of
round.Hub or knuckle out
of round or distorted.
Localized tread wear.
Once spotty wear develops in
tread due to hard braking or
abrupt starting, localized wear
tends to be accelerated.

WORKSHOP MANUAL
TF SERIES
TRANSFER

SECTION 7D

TRANSFER CASE 7D-1

SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service Precaution .......................................................................................................... 7D – 2
General Description ........................................................................................................ 7D – 3
Transfer Rear Oil Seal .................................................................................................... 7D – 4
Transfer Rear Oil Seal and Associated Parts ............................................................ 7D – 4
Removal ........................................................................................................................ 7D – 4
Installation .................................................................................................................... 7D – 4
Transfer Case Assembly ................................................................................................ 7D – 6
Transfer Case Assembly and Associated Parts ........................................................ 7D – 6
Removal ........................................................................................................................ 7D – 7
Installation .................................................................................................................... 7D – 7
Transfer Control Unit ...................................................................................................... 7D – 10
Removal ........................................................................................................................ 7D – 10
Installation .................................................................................................................... 7D – 10
Transfer Disassembly ..................................................................................................... 7D – 11
Removal ........................................................................................................................ 7D – 11
Inspection and Repair .................................................................................................. 7D – 20
Inspection and Repair (Transfer Case Assembly) ..................................................... 7D – 20
Reassembly .................................................................................................................. 7D – 24
Main Data and Specifications ........................................................................................ 7D – 33
Special Tools ................................................................................................................ 7D – 36

TRANSFER CASE 7D-33

Main Data and Specifications
General Specifications
Type Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Planetary type gears shifting between “low" and “high".
Control method Remote control with the button switch on the instrument panel for gears
shifting among “2H" , “4H" and “4L".
Gear ratio High; 1.000
Low; 2.482
Oil capacity 1.3 lit. (1.37 U.S. quart)
Type of lubricant BESCO GEAR OIL TRANSAXLE (5W-30)
Refer to chart in Section 0

Torque Specifications
Nm (kgm/lb ft)

RTW47DLF000201

TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution .................................................................................................... 7D1 - 2
General Description ................................................................................................... 7D1 - 3
System Components ................................................................................................. 7D1 - 5
Parts Location ...................................................................................................... 7D1 - 5
Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11
Parts Location ............................................................................................................ 7D1 - 23
Circuit Diagram .......................................................................................................... 7D1 - 27
Connector List ........................................................................................................... 7D1 - 31
Diagnosis .................................................................................................................... 7D1 - 34
Before determining trouble ................................................................................. 7D1 - 34
Memory erasing procedure ....................................................................................... 7D1 - 40
Diagnosis from symptom .......................................................................................... 7D1 - 41

WORKSHOP MANUAL
TF SERIES
TRANSMISSION
AW30-40LE MODEL
SECTION 7A

TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-13

CAN bus systems in automatic
transmission control (AW30-40LE)
The automatic transmission control system in AW30-
40LE uses high speed CAN bus system .The individual
CAN bus systems are connected via two interfaces and
can exchange information and data. This allows control
modules that are connected to different CAN bus
systems to communicate.
High speed CAN bus
Transmission control modules in the vehicle that require
continuous, rapid communication are connected to the
high speed CAN bus. For example, the automatic
transmission is continuously notified of the current
engine load status. Since the automatic transmission
control module has to react immediately to load status
changes, rapid communication is required between the
engine control module and the automatic transmission
control module. The high speed CAN bus in the AW30-
40LE is designed as a two-wire CAN bus (twisted pair).
The wires are shielded and twisted. The transfer rate is
500 K baud.




RUW37ASF000401
Diagnosis
Electronic Diagnosis
How To Diagnose The Problem
1. To avoid incorrect diagnostics, this book needs to
be followed accurately. Unless stated, do not jump
directly to a section that could contain the
solution. Some important information may be
missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The go to “
SECTION"
means to continue to check
going to the “section".
4. The go through “
SECTION"
means to go through
the “section" and then to go back to the place the
go through was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory o
f
electricity. This includes the meaning of voltage,
amps, ohms, and what happens in a circuit with an
open or shorted wire. You should also be able to
read and understand wiring diagrams.
Check Trans Indicator
Find CHECK TRANS indicator and verify if it is
A. Flashing: Go to DIAGNOSTIC CHECK.
B. Staying on: Go through CHECK TRANS CHECK
.
C. Is never ON when the ignition key is turned on: Go through CHECK TRANS CHECK
D. Is ON during 3 seconds at ignition but OFF after: Normal operation. No DTC or malfunction.



RTW37ASH000401
On Board Diagnostic Check
This test determines if the transmission or its input or
output connections or sensors are failing.
1. Connect the Tech 2: Go through Tech 2 OBD
CONNECTION .
2. Turn on the ignition but not the engine.
3. Push “F0" on Tech 2 to see the Diagnostic Trouble
Code (DTC):

7A2-32 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Clear DTC
NOTE: If you clear the DTC (Diagnostic Trouble
Codes) you will not be able to read any codes recorded
during the last occurrence.
NOTE: To use the DTC again to identify a problem,
you will need to reproduce the fault or the problem.
This may require a new test drive or just turning the
ignition on (this depends on the nature of the fault).
1. IF you have a Tech 2:
1. Connect the Tech 2 if it is still not connected go
through Tech 2 OBD CONNECTION.
2. Push “F1: Clear DTC Information" in the
Application Menu and answer “Yes" to the
question “Do you want to clear DTC's?"
a. When a malfunction still exists and the Tech 2 displays “AW30-40 CODES NOT
CLEARED". This means that the problem is
still there or that the recovery was not done.
Please go to DTC CHECK.
b. When a malfunction has been repaired and the recovery is done the Tech 2 displays
“ AW30-40LE CODES CLEARED".
2. When you have no Tech 2, the storaged trouble
codes can be cleared by shorting the terminals
No.11 and No.4 or 5 (ground) of data link connecto
r
with a lead wire for 1  6 seconds.
DTC Check
1. Diagnostic Trouble Codes (DTC) have been
identified by Tech 2.
2. You have written the list of the DTCs. The order o
f
the malfunctions has no meanings for this TCM.
Usually only one or two malfunctions should be set
for a given problem.
3. Check directly the DTCs you identified. The DTCs
are sorted by number. Refer to Diagnostic Trouble
Code (DTC) Identification in this section.
TCM Precaution
The TCM can be damaged by:
1. The electrostatic discharge
2. The short circuit of some terminals to voltage or to
ground.
Electrostatic Discharge Damage Description: 1. Electronic components used to control systems are often designed to carry very low voltage, and
are very susceptible to damage caused by
electrostatic discharge. It is possible for less than
100 volts of static electricity to cause damage to
some electronic components. By comparison, it
takes as much as 4,000 volts for a person to even
feel the zap of a static discharge.
2. There are several ways for a person to become
statically charged. The most common methods o
f
charging are by friction and induction. An example
of charging by friction is a person sliding across a
car seat, in which a charge of as much as 25,000
volts can build up. Charging by induction occurs
when a person with well insulated shoes stands
near a highly charged object and momentarily
touches ground. Charges for the same polarity are
drained off, leaving the person highly charged with
the opposite polarity. Static charges of either type
can cause damage, therefore, it is important to
use care when handling and testing electronic
components.
NOTE: To prevent possible electrostatic discharge
damage:
1. Do not touch the TCM connector pins or soldered
components on the TCM circuit board.
2. Be sure to follow the guidelines listed below i
f
servicing any of these electronic components:
3. Do not open the replacement part package until it is time to install the part.
4. Avoid touching electrical terminals of the part.
5. Before removing the part from its package, ground
the package to a known good ground on the
vehicle.
6.
Always touch a known good ground before handling
the part. This step should be repeated before
installing the part if the part has been handled
while sliding across the seat, while sitting down
from a standing position or while walking some
distance.
Information On TCM
1. The Transmission Control Module (TCM) is located
in the place of a clutch pedal and is the control
center of the electronic transmission control
system.
2. The TCM must be maintained at a temperature below 85

C (185

F) at all times. This is most
essential if the vehicle is put through a paint baking
process. The TCM will become inoperative if its
temperature exceeds 85

C (185

F). Therefore, it is
recommended that the TCM be removed or that
temporary insulation be placed around the TCM
during the time the vehicle is in a paint oven o
r
other high temperature process.
3. The TCM is designed to process the various inputs and then respond by sending the appropriate
electrical signals to control transmission upshift,
downshift, shift feel and torque converter clutch
engagement.
4. The TCM constantly interprets information from the
various sensors, and controls the systems that
affect transmission and vehicle performance. By
analyzing operational problems, the TCM is able to