Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 363

NOTICE

Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.

All material contained in this Manual is based on the latest
product information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.

Applicable Model : UBS 69 (For General Export)

TFS 69 (For Israel)
TFR 69 (For Israel)

This manual is applicable to 2002 year model vehicle.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-1

SECTION 7A

AUTOMATIC TRANSMISSION (AW30-40LE)

TABLE OF CONTENTS

PAGE

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 4

Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 4
Electronic Control Components . . . . . . . . . . . . . . . . . . . . 7A- 5

Transmission Control Module (TCM) . . . . . . . . . . . . . . . . . . 7A- 6
Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . 7A- 7

Control and Functions. . . . . . . . . . . . . . . . . . . . . . . . 7A- 8
Major Input/Output Components . . . . . . . . . . . . . . . . . . . ...7A- 11

Location of Clutch, Brake, One-way Clutch and Solenoid . . . . . . . . . ..7A- 12
Operation of Clutch, Brake and One-Way Clutch. . . . . . . . . . . . . .7A- 14

Speed Change and Lock-up Pattern. . . . . . . . . . . . . . . . . . ..7A- 14

Overdrive and Lock-up Operating Conditions. . . . . . . . . . . . . . ..7A- 15

Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 16

Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . ...7A- 16
Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 17

Diagnosis with Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . 7A- 20
Tech 2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 21

Tech 2 Operating Flow Chart (Start up) . . . . . . . . . . . . . . . . . 7A- 23
Intermittent Conditions. . . . . . . . . . . . . . . . . . . . . . . ...7A- 24

Data List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7A- 25
Identification of Transmission Control Module (TCM). . . . . . . . . . . .7A- 26

Diagnostic Trouble Codes (DTC) Check . . . . . . . . . . . . . . . . ...7A- 27

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 43
Connector List. . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 47

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . ...7A- 51
Manual Shifting Test . . . . . . . . . . . . . . . . . . . . . . . . ...7A- 56

Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 57
Time Lag Test. . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 58

Hydraulic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 59

INDEX

7A-2 AUTOMATIC TRANSMISSION (AW30-40LE)

Road Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 61
Shift Point Chart and Lock-Up Point Chart. . . . . . . . . . . . . . . ...7A- 64

TCM Voltage Check. . . . . . . . . . . . . . . . . . . . . . . . . .7A- 68

On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 70

Transmission Fluid Level and Condition . . . . . . . . . . . . . . . . ..7A- 70

ATF Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 70
Throttle Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . .7A- 71

Neutral Start Switch Inspection . . . . . . . . . . . . . . . . . . . . .7A- 72
Brake Signal Inspection . . . . . . . . . . . . . . . . . . . . . . . .7A- 73

Vehicle Speed Sensor 1 Inspection. . . . . . . . . . . . . . . . . . ...7A- 73
Vehicle Speed Sensor 2 Inspection. . . . . . . . . . . . . . . . . . ...7A- 73

Pattern Select Switch Inspection. . . . . . . . . . . . . . . . . . . ...7A- 74
Overdrive Switch Inspection. . . . . . . . . . . . . . . . . . . . . ..7A- 74

Solenoid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 75

ATF Temperature Sensor Inspection . . . . . . . . . . . . . . . . . . 7A- 75
Throttle Position Sensor Inspection. . . . . . . . . . . . . . . . . . ..7A- 76

Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 76
Shift Solenoid and Lock-Up Solenoid . . . . . . . . . . . . . . . . . ...7A- 78

Valve Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . .7A- 79
Rear Oil Seal (Adapter Housing, 4×

×

×

×4) . . . . . . . . . . . . . . . . . ..7A- 82

Rear Oil Seal (Extension Housing, 4×

×

×

×2) . . . . . . . . . . . . . . . . ..7A- 82

Transmission Removal and Installation. . . . . . . . . . . . . . . . . 7A- 83

Unit Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 90

Disassembly of Major Components (1) . . . . . . . . . . . . . . . . . .7A- 92

Reassembly of Major Components (1) . . . . . . . . . . . . . . . . . ..7A- 94

Disassembly of Major Components (2) . . . . . . . . . . . . . . . . . .7A- 97
Reassembly of Major Components (2) . . . . . . . . . . . . . . . . . ..7A-102

Disassembly of Major Components (3) . . . . . . . . . . . . . . . . . .7A-108
Reassembly of Major Components (3) . . . . . . . . . . . . . . . . . ..7A-117

Disassembly, Inspection and Reassembly of Minor Components . . . . . . .7A-130
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-131

OD Planetary Gear and OD Direct Clutch Assembly (C-0). . . . . . . . . ...7A-136
OD Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7A-146

Direct Clutch Assembly (C-2). . . . . . . . . . . . . . . . . . . . . .7A-151
Forward Clutch Assembly (C-1). . . . . . . . . . . . . . . . . . . . .7A-157

AUTOMATIC TRANSMISSION (AW30-40LE) 7A-3

Front Planetary Gear. . . . . . . . . . . . . . . . . . . . . . . . ...7A-165
Planetary Sun Gear and No.1 One-Way Clutch . . . . . . . . . . . . . . 7A-169

Second Brake Assembly (B-2) . . . . . . . . . . . . . . . . . . . . ...7A-174

Rear Planetary Gear Assembly and Output Shaft . . . . . . . . . . . . . 7A-178
First and Reverse Brake Assembly (B-3) . . . . . . . . . . . . . . . . ..7A-185

Transmission Valve Body Assembly. . . . . . . . . . . . . . . . . . .7A-191
Lower Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . ...7A-195

Upper Valve Body. . . . . . . . . . . . . . . . . . . . . . . . . . 7A-207
Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . .7A-223

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-227
Adapter Housing (4×

×

×

×4) . . . . . . . . . . . . . . . . . . . . . . . ..7A-228

Extension Housing (4×

×

×

×2). . . . . . . . . . . . . . . . . . . . . . ...7A-230

Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . .7A-232

General Specifications . . . . . . . . . . . . . . . . . . . . . . . ...7A-232

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . .7A-233

Special Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-236

CAUTION:
When fasteners are removed, always reinstall them
at a the same location from which they were
removed. If a fastener needs to be replaced, use
the correct part number fastener for that
application. If the correct part number fastener is
not available, a fastener of equal size and strength
(or stronger) may be used.

Fasteners that are not reused, and those requiring
thread locking compound, will be called out. The
correct torque values must be used when installing
fasteners that require torque. If the above
conditions are not followed, parts or system
damage could result.