Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1778

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 –

8

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 gear

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.

ON-VEHICLE SERVICE (JR405E) 7A3-3

Cold Level

The vehicle must not have been driven so that the
temperature reaches around 20

°

C (68

°

F) before the

cold level check is made.

1. Park the vehicle on a level surface.

2. Apply the parking brake firmly.

3. Start the engine and allow it to warm up.

The engine coolant temperature gauge needle

should be midway between the “C” mark and “H”

mark.

4. Let the engine run at idle.

Move the select lever slowly through all the gear

ranges.

Stop in each range just long enough for the

transmission to engage.

5. Return the select lever either “P” or “N”.

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 “C” range on the

dipstick.

If the ATF level is below the “C” range, ATF must be

added.

242R300002

ATF CHANGE

1. Start the engine and allow it to idle until the ATF

reaches a temperature of 40-50

°

C

2. Park the vehicle on level ground and block the

wheels.

3. Stop the engine.

4. Raise vehicle and support with suitable safety

stands.

5. Remove the drain plug from the oil pan and drain the

ATF (approximately 6 liters).

6. Remove the oil pan.

7. Inspect the oil pan (details written below).

8. Install the oil pan.
Note:
Use new gasket. Clean the oil pan and magnet.

Oil pan bolt torque : 8 N

⋅

m (69 lb

⋅

in)

9. Replace the gasket and install the drain plug.

Drain plug torque : 35 N

⋅

m (26 lb

⋅

ft)

Note:
Do not reuse old washer (gasket).

Clean the drain plug (especially the threaded section).

10. Pour about 5 liters of new ATF. Then, add more ATF

carefully as necessary using the dipstick.

Refer

to

“ATF LEVEL” previously in this section.

Note:
Keep the engine idle (do not stop it) during the oil level
adjustment.

11. Remove the safety stands and wheel blocks.

Inspect

1. Check the drain plug tip for adhesion of foreign

substances.

2. Check the drained ATF for color, smell and inclusion

of foreign substances.

3. Check the oil pan bottom and magnet for adhesion of

foreign substances.

If a problem is discovered during those checks, the

Automatic transmission must be overhauled.

Note:
The torque converter and the oil strainer need replaced
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.

In addition, flush the ATF cooler circuit

7A3-4 ON-VEHICLE SERVICE (JR405E)

TRANSMISSION CONTROL MODULE (TCM)

RTW37ALF001901

Remove and Disconnect

1. Disconnect the negative battery cable.

2. Remove the connectors.

3. Remove the fixing nuts and remove the TCM (1)

from the bracket.

Note:
The TCM is fitted under instrument panel of the driver’s
compartment by means of three stud bolts.

Install or Connect

Follow the removal steps in the reverse order. Be
absolutely sure that the connectors are securely
fastened.

AT CONT