ISUZU AW03-72LE Automatic Transmission AUTO Gearbox Manual

FOR SERVICE TRAINING AUTOMATIC TRANSMISSION (AW03-72LE) ISUZU MOTORS LIMITED

AW03-72LE Automatic Transmission-1 MAIN DATA & SPECIFICATION Model AW03-72LE Torque Converter Type Three Elements, One Stage & Two Phase Type with Lock-up Function Name ATF DEXRON II or III Quantity Approximately 6.5L ATF Cooling System Water Cooled Type (Radiator) 1 st 2.826 2 nd 1.493 3 rd 1.000 4 th (Over Drive) 0.688 Gear Ratio Reverse 2.703 One-way Clutch No. 1 F-1 18 One-way Clutch No. 2 F-2 26 Clutch Over Drive One-way Clutch F-0 20 Number of Sprag Forward Clutch C-1 4 Direct Clutch C-2 3 Over Drive Direct Clutch C-0 2 Second Coast Brake B-1 2 Second Brake B-2 3 First & Reverse Brake B-3 5 Friction Element Over Drive Brake B-0 3 Number of Disc

AW03-72LE Automatic Transmission-2 SYSTEM DIAGRAM Vehicle Speed Sensor (SP1) Detects output shaft revolution seed and send signal to TCM and speedometer. Vehicle Speed Sensor (SP2) Detects output shaft revolution seed and send signal to TCM. Throttle Position Sensor Detects injection pump lever operating angle and send signal to TCM. Inhibitor Switch Detects select lever position and send signal to TCM. Over Drive Switch Detects overdrive request switch selected by driver and send signal to TCM. Input Brake Switch Detects brake pedal operated by driver and send signal to TCM. TCM Judges necessary line pressure, gear shifting point and lock-up operation based on electrical signals from switches and sensors and send appropriate signals to solenoids. Shift Solenoid (S1 & S2) Selects appropriate gear shifting position for current driving condition based on signal from TCM. Lock-up Solenoid (S3) Regulates lock-up pressure for current driving condition based on signal from TCM. Output CHECK TRANS Indicator Lamp Indicates CHECK TRANS indicator lamp in case of malfunction. 8. Brake Pedal -Brake Switch 3. 5. Meter -CHECK TRANS Indicator Lamp -Speedometer 1. Transmission Control Module (TCM) 4. Select Lever -Over Drive Switch 9. Data Link Connector (DLC) 6. Engine -Throttle Position Sensor 2. Transmission -Inhibitor Switch -Vehicle Speed Sensor (SP1) -Vehicle Speed Sensor (SP2) -Shift Solenoid (S1 & S2) -Lock-up Solenoid (S3) 7. Electrical Source -Ignition Voltage -Battery

AW03-72LE Automatic Transmission-3 LOCATION & OPERATION OF CLIUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID C0: Over Drive Direct Clutch C1: Forward Clutch C2: Direct Clutch B0: Over Drive Brake B1: Second Coast Brake B2: Second Brake B3: First & Reverse Brake F0: Over Drive One-way Clutch F1: One-way Clutch (No. 1) F2: One-way Clutch (No. 2) Clutch Brake One-way Clutch Solenoid Select Lever Position Gear Position Gear Shift Lock- up C-0 C-1 C-2 B-0 B-1 B-2 B-3 F-0 F-1 F-2 S1 S2 S3 P - O O R - O O O O O N - O O 1 st O O O O O 2 nd O O O O O O O 3 rd O O O O O O O O D 4 th (O/D) O O O O O O 1 st O O O O O 2 nd O O O O O O O O 2 3 rd O O O O O O 1 st O O O O O O 2 nd O O O O O O O O L 3 rd O O O O O O

AW03-72LE Automatic Transmission-4 CONTENTS OF FUNCTION & CONTROL Item Description Gear Shift Control The TCM issues a shift solenoid drive signal based on the inhibitor switch, vehicle speed and throttle opening. And, the TCM control shift schedule according to the preset shift map. In order to prevent engine over running, the TCM achieves up shift control 3 rd to 4 th when the vehicle speed is more than 110km/h even over drive (O/D) is tuned off. It will return 4 th to 3 rd when the vehicle speed is less than 100km/h. Lock-up Control The lock-up solenoid adjusts the pressure based on the signal from the TCM according to the vehicle speed, throttle opening, select lever position based on the preset lock-up point to control the lock-up. The lock-up is disengaged when the throttle is closed or brake pedal is depressed. Squat Control At garage shift, shift to the 1 st gear sequentially after shifting into the 3 rd gear first to improve the garage shift shock. Fail-safe Function In case of malfunction of sensors, solenoid, TCM automatically begins fail-safe control to minimize effects on driving. 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 warm the driver. The trouble code is memorized into the TCM. SHIFT SOLENOID FAIL-SAFE FUNCTION Normal Solenoid S1 Malfunction Solenoid S2 Malfunction S1& S2 Malfunction Select Lever Position S1 S2 Gear Position S1 S2 Gear Position S1 S2 Gear Position S1 S2 Gear Position O 1 st X O 3 rd O X 1 st X X 4 th (O/D) O O 2 nd X O 3 rd X 4 th (O/D) X X 4 th (O/D) O 3 rd X O 3 rd X 4 th (O/D) X X 4 th (O/D) D 4 th (O/D) X 4 th (O/D) X 4 th (O/D) X X 4 th (O/D) O 1 st X O 3 rd O X 1 st X X 3 rd O O 2 nd X O 3 rd X 3 rd X X 3 rd 2 O 3 rd X O 3 rd X 3 rd X X 3 rd O 1 st X 3 rd O X 1 st X X 3 rd L O O 2 nd X 3 rd O X 1 st X X 3 rd

AW03-72LE Automatic Transmission-5 TCM PIN ASSIGNMENT TCM voltage check is done to check for transmission and TCM problems which cannot be detected by self- diagnosis. Additionally, it severs as a back-up check for self-diagnosis. Measure the voltage drop and make a continuity test for each of sensors, solenoids and switches. If the voltage is within the specified range and continuity exists, that particular area of the TCM and transmission assembly is normal. If voltage deviation or lack of continuity is discovered, disconnect the applicable parts and check of them individually. Pin Pin Name Input / Output Connected to Measurement Condition Standard At L range 10 – 15 volts 1 L Range Switch Input Inhibitor Switch Other than L range Less than 1 volt At 2 Range 10 – 15 Volts 2 2 Range Switch Input Inhibitor Switch Other than 2 range Less than 1 volt At N Range 10 – 15 volts 3 N Range Switch Input Inhibitor Switch Other than N range Less than 1 volt 4 Not Used - - - - 5 Not Used - - - - 6 Vehicle Speed Sensor (SP1) Input Vehicle Speed Sensor (SP1) At run in L range in 1 st gear 20km/h Pulse generated (Approximately 5.6 volts by AC range) 7 Not Used - - - - 8 Throttle Position Sensor Ground - Throttle Position Sensor - Continuity with ground Switch depressed (Over Drive ON) 10 – 15 volts 9 Over Drive Off Switch Input O/D Off Switch Switch not depressed (Over Drive OFF) Less than 1 volt 10 Keyword 2000 Serial Data Communication Input / Output Data Link Connector No. 7 - -

AW03-72LE Automatic Transmission-6 Pin Pin Name Input / Output Connected to Measurement Condition Standard At lock-up 10 – 15 volts 11 Lock-up Solenoid Output Lock-up Solenoid Other than lock-up Less than 1 volt At 2 nd , 3 rd gear 10 – 15 volts 12 Shift Solenoid S2 Output Shift Solenoid S2 At 1 st , 4 th gear Less than 1 volt At 1 st , 2 nd gear 10 – 15 volts 13 Shift Solenoid S1 Output Shift Solenoid S1 At 3 rd , 4 th gear Less than 1 volt Pedal depressed 10 – 15 volts 14 Brake Switch Input Brake Switch Pedal released Less than 1 volt 15 Not Used - - - - 16 Not Used - - - - 17 Not Used - - - - Pedal released (Idle position) Approximately 0.45 volts 18 Throttle Position Sensor Signal Input Throttle Position Sensor Pedal fully depressed (WOT) Approximately 3.50 volts Lamp turned ON Less than 1 volt 19 Check Trans Indicator Lamp Output CHECK TRANS Indicator Lamp Lamp turned OFF 10 – 15 volts 20 Throttle Position Sensor Voltage Supply Output Throttle Position Sensor Ignition switch ON Approximately 5 volts 21 Diagnosis Request Switch Input Data Link Connector No. 11 - - 22 Vehicle Speed Sensor (SP2) High Input Vehicle Speed Sensor (SP2) At run in L range in 1 st gear 20km/h Pulse generated (Approximately 0.48 by AC range) 23 Vehicle Speed Sensor (SP2) Low Input Vehicle Speed Sensor (SP2) Ignition switch OFF and measure pins 22 and 23 Approximately 370 ohms 24 Ground - Body Ground - Continuity with ground 25 Battery Voltage Supply Input Battery All time 10 – 15 volts 26 Ignition Voltage Supply Input Ignition Switch Ignition Switch ON 10 – 15 volts

AW03-72LE Automatic Transmission-7 CHECK TRANS INDICATOR LAMP "CHECK TRANS" is ON during 3 seconds at key switch ON position. When trouble has occurred to electrical components, "CHECK TRANS" lamp is blinked (1.25 Hz) even during driving to warn the driver. The trouble is recorded by trouble code in TCM. When temporary trouble code has been canceled, the "CHECK TRANS" lamp stops blinking. This blinking can be stopped by setting the key off. But the trouble code remains memorized in TCM. SELF-DIAGNOSIS CODE (FLASH CODE) DISPLAY Indication Method: Terminal No. 11 and No. 4 or 5 (ground) of data link connector are short circuited. Turn the key switch to the ON position. In case no trouble code existence, "CHECK TRANS" lamp is blinked (1.25 Hz). In case the plural trouble codes have occurred at a time, each code are indicated three times in numerical order. Trouble Code Clear Method: If you have Tech 2: Follow the procedure instructed on the Tech 2. Note: If you clear the DTC you will not be able to read any codes recorded during the last occurrence. 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 key switch on (this depends on the nature of the fault). Key SW ON OFF ON 3 sec. (Lamp Check) Normal Abnormal (DTC Stored) 3.2 sec. 0.4 sec. 0.4 sec. CHECK TRANS Normal Trouble Code (32) Self-diagnosis Start 0.4Sec. 0.4Sec. 3.2Sec. 0.4Sec. 0.4Sec. 3.2Sec. 1.2Sec. 3.2Sec.

AW03-72LE Automatic Transmission-8 DIAGNOSIS WITH TECH 2 Getting Started Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The PCMCIA card (1) inserts into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5). 4. Make sure the ignition switch is OFF. 5. Connect the Tech 2 SAE 16/19 (3) adapter to the vehicle data link connector (DLC). 6. Turn the ignition ON and press the “PWR” key of the Tech 2. 7. Verify the Tech 2 power up display. Operating Procedure 1. Press Enter at start screen. 2. Select “F0 Diagnostic” then press Enter. 3. Select the appropriate vehicle identification. 4. Select “F0 Powertrain” then press Enter. 5. Select “AW03-72LE”. The following table shows, which functions are used the available equipment version. F0: Diagnostic Trouble Codes The purpose of the "Diagnostic Trouble Codes" mode is to display stored trouble code in the TCM. When "Clear DTC Information" is selected, a "Clear DTC Information", warning screen appears. This screen informs you that by cleaning DTC's "all stored DTC information in the TCM will be erased". F1: Data Display The purpose of the "Data Display" mode is to continuously monitor data parameters. The current actual values of all important sensors and signals in the system are display through F1 mode. F2: Snapshot "Snapshot" allows you to focus on making the condition occur, rather than trying to view all of the data in anticipation of the fault. The snapshot will collect parameter information around a trigger point that you select. F3: Miscellaneous Test The purpose of "Miscellaneous Test" mode is to check for correct operation of electronic system actuators. Check Light Test The purpose of this test is for checking whether the CHECK TRANS indicator lamp is operated when it commanded ON. Faulty circuit(s) or opened bulb could be considered when not operating with commanded ON. F0: Diagnostic Trouble Codes F0: Read DTC Info By Priority F1: Read DTC Info As Stored By ECU F2: Clear DTC Information F1: Data Display F2: Snapshot F3: Miscellaneous Tests F0: Lamps F0: Check Light Test F1: Solenoids F0: Solenoid 2-3 Test F1: Solenoid 1-2/3-4 Test F2: TCC Solenoid Test 1 2 4 3 5

AW03-72LE Automatic Transmission-9 Solenoid 2-3 Test The purpose of this test for checking whether the shift solenoid S1 is operated when it commanded ON/OFF. Faulty shift solenoid S1 could be considered that does not create clicking noise (solenoid operating noise), interrupted noise or abnormal noise when commanded ON. Solenoid 1-2/3-4 Test The purpose of this test for checking whether the shift solenoid S2 is operated when it commanded ON/OFF. Faulty shift solenoid S2 could be considered that does not create clicking noise (solenoid operating noise), interrupted noise or abnormal noise when commanded ON. TCC Solenoid Test The purpose of this test for checking whether the lock-up solenoid S3 is operated when it commanded ON/OFF. Faulty lock-up solenoid S3 could be considered that does not create clicking noise (solenoid operating noise), interrupted noise or abnormal noise when commanded ON.

ISUZU AW03-72LE Automatic Transmission AUTO Gearbox Manual

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