2004 ISUZU TF SERIES automatic transmission

7A3-50 ON-VEHICLE SERVICE (AW30 –40LE)

Major Components
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component
group during assembly, inspect and repair this group
immediately.
General Assembly Notes:
1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful
inspection before assembly because even a small
nick could cause fluid leakage or affect
performance.


2. Before assembling new clutch discs and brake
bands, soak them in automatic transmission fluid fo
r
at least thirty minutes.
3.
Apply automatic transmission fluid on the sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in thei
r
palces.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.



Bearing and Race

RUW36AM F000201

UNIT REPAIR (AW30–40LE) 7A4–37
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the nex t
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.

CONSTRUCTION AND FUNCTION 7A1-3

DESCRIPTION
CONSTRUCTION



































1 Converter Housing 6 Low Clutch 11 Oil Pump
2 Torque Converter 7 Low & Reverse Brake 12 Control Valve
3 High Clutch 8 Output Shaft 13 Low One-way Clutch
4 Reverse Clutch 9 Extension Housing 14 Parking Gear
5 2-4 Brake 10 Input Shaft

Figure 1. Construction of Automatic Transmission

The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module
(TCM). There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift
Control: DESC) using a duty cycle type solenoid, which ensures high shift quality.
This transmission also controls learning and constantly checks the time of each clutch and brake required for
the speed change to match this time with the target value for the optimum speed change.

The TCM will automatically select the most appropriate shift points and lock-up points depending on the
throttle opening angle, the vehicle speed and the vehicle load.
If any trouble arises in the vehicle sensor, throttle sensor, solenoid, etc., the fail-safe control function is
activated to keep the running performance.
Problems with the sensors, the solenoids can be quickly detected with the self diagnosis procedure described
in this manual.

The JR405E automatic transmission consists of the torque converter, the oil pump, the input shaft, the out put
shaft, the planetary gears and the control valve.
The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two
multiple plate brakes and a one-way clutch.
2WD
4WD

7A1-28 CONSTRUCTION AND FUNCTION
Item Description
Fail-safe function In case of malfunction of the vehicle speed sensor, throttle position sensor, all solenoids or
inhibitor switch, TCM automatically begins fail-safe control to minimize effects on driving.
The gear is fixed at the 3rd-speed position and power supply to the solenoid is shut off so
that the solenoid does not work nor lock up.
Self-diagnosis function Parts required for controlling the automatic transmission are provided with a self-diagnosis
function. When any trouble occurs, the check trans indicator lamp blinks to warn the driver.
The trouble code is memorized in the TCM.

7A2-6 DIAGNOSIS (JR405E)
BASIC TROUBLE SHOOTING

Transmission fluid pressure together with clutch and brake friction and other important transmission functions are
controlled by electrical signal from the Transmission Control Module (TCM).
Random diagnosis can produce inaccurate and misleading indications. It is important that diagnosing procedure be
carried out systematically.
Carefully follow the sequence outlined below to diagnose automatic transmission assembly.




Verify Customer Complain
Preliminary Check
(Visual Check/Test Drive)
Compare to Same Model
(If Available)
Check Service Bulletin
DTC Check
(Self-diagnosis/Tech 2)
Go to Symptom Diagnosis
Stall Test
Line Pressure Test
Transmission Overhaul
Repair & Verify Fix
Transmission Overhaul
Transmission Overhaul
Go to DTC Chart
Go to Intermittent Diagnosis NG
Follow the instructions
NG
No Instruction
NG
OK
NO DTC
Not Solved
OK
OK
Follow the Bulletin
(Once Clear Memory) Restored
Not Stored
Use Service Programming
System (SPS)
Not Solved

DIAGNOSIS (JR405E) 7A2-9
DIAGNOSIS WITH TECH 2
In this JR405E transmission, troubleshooting can be performed for electrical faults using the Tech 2 scan tool.
If the "CHECK TRANS" lamp blinks, or if an electrical fault in the transmission may probably exit, check trouble
codes using the Tech 2 scan tool.
In the diagnostic procedures described in this manual, first repair the faulty positions indicated by trouble code in
order of numbers and then perform troubleshooting for the faulty positions that are not indicated by trouble code.
For correct troubleshooting, it is necessary to first repair the trouble codes of lower order numbers, then to repair
the trouble codes of higher order numbers in sequence.

If no codes are set:

Refer to F1: Data Display and identify the electrical faults that are not indicated by trouble code.

Refer to "SYMPTOM DIAGNOSIS".

If codes are set:
1. Record all trouble codes displayed by Tech 2 and check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is intermittent. In this case, refer to "INTERMITTENT
DIAGNOSIS".
6. If a code is present, refer to DTC Chart for diagnosis.
7. Check trouble codes again using the Tech 2.





TECH 2 CONNECTION
Tech 2 scan tool is used to electrically diagnose the automatic
transmission system and to check the system. The Tech 2
enhances the diagnosis efficiency though all the
troubleshooting can be done without the Tech 2.
1. Configuration of Tech 2

Tech 2 scan tool kit (No. 7000086), Tech 2 scan tool
(No. 7000057) and DLC cable (No. 3000095).

SAE 16/19 adapter (No. 3000098) (1), RS232 loop back
connector (No. 3000112) (2) and PCMCIA card (No.
3000117) (3).




2. Tech 2 Connection

Check the key switch is turn OFF.

Insert the PCMCIA card (1) into the Tech 2 (4).

Connect the SAE 16/19 adapter (2) to the DLC cable (3).

Connect the DLC cable (3) to the Tech 2 (4).

Connect the SAE 16/19 adapter (2) to the data link
connector of the vehicle.

Turn the key switch of the vehicle ON and press the
"PWR" key of the Tech 2.

Check the display of the Tech 2.

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 – 2
ATF Level ......................................................................................................................... 7A3 – 2
ATF Change ..................................................................................................................... 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 4
Throttle Position Sensor ................................................................................................ 7A3 – 5
Inhibitor Switch ............................................................................................................... 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ................................................................................................................ 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever ..................................................................................................................... 7A3 –10
Shift Cable ....................................................................................................................... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20

7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.



AUTOMATIC TRANSMISSION FLUID (ATF)
Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch band
and other parts.
The transmission control module, the transmission unit,
and the vehicle must be carefully checked if gum or
varnish is present.




ATF LEVEL
Inspect
Hot Level
1. Warm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80
C (176
F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each gear range just long enough for the
transmission to engage.
5. Return the select lever to either “P” or “N”.
C07RW009
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.
9. Remove the dipstick.
The ATF level should be inside the “H” range on the
dipstick.
242R300001
If the ATF level is below the “H” range, ATF must be
added.