Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 288

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

SECTION 7A

AUTOMATIC TRANSMISSION (AW30-40LE)

TABLE OF CONTENTS

PAGE

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 5

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

Transmission Control Module (TCM) . . . . . . . . . . . . . . . . . . 7A- 9
Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . 7A- 11

Control and Functions. . . . . . . . . . . . . . . . . . . . . . . . 7A- 13
Major Input/Output Components . . . . . . . . . . . . . . . . . . . ...7A- 15

Location of Clutch, Brake, One-way Clutch and Solenoid . . . . . . . . . ..7A- 16
Operation of Clutch, Brake and One-Way Clutch. . . . . . . . . . . . . .7A- 18

Speed Change and Lock-up Pattern. . . . . . . . . . . . . . . . . . ..7A- 18

Overdrive and Lock-up Operating Conditions. . . . . . . . . . . . . . ..7A- 19

Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 20

Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . ...7A- 20
Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 21

Diagnosis with Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . 7A- 25
Tech 2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 26

Tech 2 Operating Flow Chart (Start up) . . . . . . . . . . . . . . . . . 7A- 28
Transmission Data . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 30

TCC Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 31
Intermittent Conditions. . . . . . . . . . . . . . . . . . . . . . . ...7A- 32

Identification of Transmission Control Module (TCM). . . . . . . . . . . .7A- 33

Diagnostic Trouble Codes (DTC) Check . . . . . . . . . . . . . . . . ...7A- 34
DTC P0120 (Flashing Code 21) Analog Throttle Signal Failure (VTH) (For UBS) ..7A- 35

DTC P0502 (Flashing Code 24) Speed Meter Sensor Failure (SP1) . . . . . . 7A- 38
DTC P0705 (Flashing Code 17) Gear Selector Failure (PRND2L). . . . . . . 7A- 41

DTC P0710 (Flashing Code 16) Oil Temperature Sensor Failure (OT2). . . . ..7A- 45
DTC P0717 (Flashing Code 14) Input Revolution Sensor Failure (NC0). . . . .7A- 48

DTC P0722 (Flashing Code 11) Output Revolution Sensor Failure (SP2) . . . ..7A- 52

INDEX

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

DTC P0727 (Flashing Code 13) Engine Revolution Signal Failure (NE) . . . . .7A- 55
DTC P0743 (Flashing Code 33) Torque Converter Clutch Control Lock-up (ON/OFF)

Solenoid Failure (SL) . . . . . . . . . . . . . . . . . . . . . . ...7A- 58

DTC P0748 (Flashing Code 35) Pressure Control Solenoid Failure (STH). . . .7A- 62
DTC P0753 (Flashing Code 31) Solenoid 1 Failure (S1). . . . . . . . . . ...7A- 66

DTC P0758 (Flashing Code 32) Solenoid 2 Failure (S2). . . . . . . . . . ...7A- 71
DTC P1120 (Flashing Code 22) PWM Throttle Signal Failure (TH) (For TFR/S) . .7A- 75

DTC P1121 (Flashing Code 23) Analog Throttle Signal Failure (VREF, VGND)

(ForUBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A- 79

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 81
Connector List. . . . . . . . . . . . . . . . . . . . . . . . . . . .7A- 87

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . ...7A- 93
Manual Shifting Test . . . . . . . . . . . . . . . . . . . . . . . . ...7A- 99

Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-100

Time Lag Test. . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-101
Hydraulic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A-102

Road Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A-103
Shift Point Chart and Lock-Up Point Chart. . . . . . . . . . . . . . . ...7A-107

TCM Voltage Check. . . . . . . . . . . . . . . . . . . . . . . . . .7A-113
TCM Standard Voltage. . . . . . . . . . . . . . . . . . . . . . . . 7A-114

On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-116

Transmission Fluid Level and Condition . . . . . . . . . . . . . . . . ..7A-116

ATF Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7A-116
Neutral Start Switch Inspection . . . . . . . . . . . . . . . . . . . . .7A-117

Brake Signal Inspection . . . . . . . . . . . . . . . . . . . . . . . .7A-118

Vehicle Speed Sensor Inspection. . . . . . . . . . . . . . . . . . . ..7A-118
Input and Output Revolution Sensor Inspection. . . . . . . . . . . . . ..7A-118

Pattern Select Switch Inspection. . . . . . . . . . . . . . . . . . . ...7A-119
Overdrive Switch Inspection. . . . . . . . . . . . . . . . . . . . . ..7A-119

Solenoid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7A-120
ATF Temperature Sensor Inspection . . . . . . . . . . . . . . . . . . 7A-120

Throttle Position Sensor Inspection (UBS and TFR/S) . . . . . . . . . . . 7A-121
Throttle Position Sensor Inspection (’01 TFR) . . . . . . . . . . . . . . .7A-122

Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A-122
Transmission Control Module (TCM) . . . . . . . . . . . . . . . . . . 7A-125

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

Shift Solenoid and Lock-Up Solenoid . . . . . . . . . . . . . . . . . ...7A-126
Valve Body Assembly and Pressure Control Solenoid. . . . . . . . . . . 7A-127

Rear Oil Seal (Adapter Housing, 4×

×

×

×4) . . . . . . . . . . . . . . . . . ..7A-129

Rear Oil Seal (Extension Housing, 4×

×

×

×2) . . . . . . . . . . . . . . . . ..7A-129

Transmission Removal and Installation (UBS). . . . . . . . . . . . . . .7A-130

Transmission Removal and Installation (TFR/S). . . . . . . . . . . . . ..7A-136

Unit Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-143

Major Components. . . . . . . . . . . . . . . . . . . . . . . . . ..7A-143
Disassembly of Major Components (1) . . . . . . . . . . . . . . . . . .7A-145

Reassembly of Major Components (1) . . . . . . . . . . . . . . . . . ..7A-147
Disassembly of Major Components (2) . . . . . . . . . . . . . . . . . .7A-150

Reassembly of Major Components (2) . . . . . . . . . . . . . . . . . ..7A-154
Disassembly of Major Components (3) . . . . . . . . . . . . . . . . . .7A-160

Reassembly of Major Components (3) . . . . . . . . . . . . . . . . . ..7A-169

Disassembly, Inspection and Reassembly of Minor Components . . . . . . .7A-183
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-184

OD Planetary Gear and OD Direct Clutch Assembly (C-0). . . . . . . . . ...7A-189
OD Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7A-199

Direct Clutch Assembly (C-2). . . . . . . . . . . . . . . . . . . . . .7A-204
Forward Clutch Assembly (C-1). . . . . . . . . . . . . . . . . . . . .7A-211

Front Planetary Gear. . . . . . . . . . . . . . . . . . . . . . . . ...7A-220
Planetary Sun Gear and No.1 One-Way Clutch . . . . . . . . . . . . . . 7A-224

Second Brake Assembly (B-2) . . . . . . . . . . . . . . . . . . . . ...7A-229
Rear Planetary Gear Assembly and Output Shaft . . . . . . . . . . . . . 7A-233

First and Reverse Brake Assembly (B-3) . . . . . . . . . . . . . . . . ..7A-240

Transmission Valve Body Assembly. . . . . . . . . . . . . . . . . . .7A-246
Lower Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . ...7A-251

Upper Valve Body. . . . . . . . . . . . . . . . . . . . . . . . . . 7A-267
Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . .7A-281

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-285
Adapter Housing (4×

×

×

×4) . . . . . . . . . . . . . . . . . . . . . . . ..7A-286

Extension Housing (4×

×

×

×2). . . . . . . . . . . . . . . . . . . . . . ...7A-288

Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . .7A-290

General Specifications . . . . . . . . . . . . . . . . . . . . . . . ...7A-290
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . .7A-291

7A-4 AUTOMATIC TRANSMISSION (AW30-40LE)

Special Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7A-295

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.