2002 WT5500 FRR S1000 Transmission Gearbox Service / Workshop Manual - PDF DOWNLOAD

SECTION 7

TRANSMISSION AND CLUTCH CONTENTS SUBJECT

PAGE

Automatic Transmission (S1000 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 2002 Service Manual Diagnosis (S1000 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2-1 Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 1997 Service Manual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 1997 Service Manual

DIAGNOSIS 7A2–1

SECTION 7A2

DIAGNOSIS (S1000 TRANSMISSION) CONTENTS SUBJECT

PAGE

Identification of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–3 Identification of Transmission Control Module (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–4 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–5 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–6 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–8 Diagnosis by Using Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–10 Data Link Connector (DLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–10 Verifying Vehicle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–10 Reading Diagnostic Trouble Codes Using a Tech2 of Other Scan Tool. . . . . . . . . . . . . . . . . . . . . . 7A2–10 Clearing Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–10 Tech2 Scan Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–11 Tech2 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–11 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–12 Operating Procedure (For example). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–12 Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–14 DTC List and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–14 DTC P0218 Transmission Fluid Over Temperature Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–16 DTC P0562 System Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–19 DTC P0563 System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–22 DTC P0602 TCM Not Programmed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–25 DTC P0705 Transmission Range Sensor Circuit (PRNDL Input). . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–26 DTC P0706 Transmission Range Sensor Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–29 DTC P0708 Transmission Range Sensor Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–32 DTC P0711 Transmission Fluid Temperature Sensor Circuit – Performance . . . . . . . . . . . . . . . . . 7A2–35 DTC P0712 Transmission Fluid Temperature Sensor Circuit – Low Input (High Temperature). . . 7A2–38 DTC P0713 Transmission Fluid Temperature Sensor Circuit – High Iput (Low Temperature) . . . . 7A2–41 DTC P0716 Turbine Speed Sensor Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–44 DTC P0717 Turbine Speed Sensor Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–47 DTC P0721 Output Speed Sensor Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–50 DTC P0722 Output Speed Sensor Circuit No Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–53 DTC P0726 Engine Speed Input Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–56 DTC P0727 Engine Speed Input Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–59 DTC P0731 Incorrect 1st Gear Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–62 DTC P0732 Incorrect 2nd Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–65 DTC P0733 Incorrect 3rd Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–68 DTC P0734 Incorrect 4th Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–71 DTC P0735 Incorrect 5th Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–74 DTC P0736 Incorrect Reverse Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–77 DTC P0741 Torque Converter Clutch System Stuck Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–80 DTC P0742 Torque Converter Clutch System Stuck On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–83 DTC P0748 Pressure Control Solenoid A Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–86 DTC P0763 Shift Solenoid C Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–89

7A2–2 DIAGNOSIS DTD P0768 Shift Solenoid D Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–92 DTC P0773 Shift Solenoid E Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–95 DTC P0778 Pressure Control Solenoid B Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–98 DTC P0840 Transmission Pressure Switch Solenoid C Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–101 DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open . . . . . . . . . . . . . . . . . 7A2–105 DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed . . . . . . . . . . . . . . . . 7A2–109 DTC P0843 Transmission Pressure Switch Solenoid C Circuit High . . . . . . . . . . . . . . . . . . . . . . . 7A2–113 DTC P0845 Transmission Pressure Switch Solenoid D Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–117 DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open . . . . . . . . . . . . . . . . . 7A2–121 DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed . . . . . . . . . . . . . . . . 7A2–125 DTC P0848 Transmission Pressure Switch Solenoid D Circuit High . . . . . . . . . . . . . . . . . . . . . . . 7A2–129 DTC P1709 Transmission Pressure Switch Solenoid E Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–133 DTC P1710 Transmission Pressure Switch Solenoid E Circuit Stuck Open . . . . . . . . . . . . . . . . . 7A2–137 DTC P1711 Transmission Pressure Switch Solenoid E Circuit Stuck Closed . . . . . . . . . . . . . . . . 7A2–141 DTC P1712 Transmission Pressure Switch Solenoid E Circuit High . . . . . . . . . . . . . . . . . . . . . . . 7A2–145 DTC P1713 Transmission Pressure Switch Reverse Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–149 DTC P1714 Transmission Pressure Switch Reverse Circuit Stuck Open. . . . . . . . . . . . . . . . . . . . 7A2–153 DTC P1715 Transmission Pressure Switch Reverse Circuit Stuck Closed . . . . . . . . . . . . . . . . . . 7A2–157 DTC P1716 Transmission Pressure Switch Reverse Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–161 DTC P1720 Solenoid A Controlled Clutch Not Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–165 DTC P1721 Solenoid B Controlled Clutch Not Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–168 DTC P1723 Solenoid A Controlled Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–171 DTC P1724 Solenoid B Controlled Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–174 DTC P1726 Shift Solenoid D Controlled Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–177 DTC P1727 Shift Solenoid E Controlled Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–180 DTC P1760 TCM Supply Voltabe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–183 DTC P1860 Torque Converter Clutch Pulse Width Modulation (PWM) Solenoid Circuit – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–186 DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal Low Input . . 7A2–189 DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal High Input. . 7A2–191 DTC U1016 Class 2 Powertrain Controller State of Health Failure . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–193 DTC U1300 Serial Data Communication Link Low (Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–195 DTC U1301 Serial Data Communication Link High (Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–197 DTC Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–200 DTC Reference Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–201 General Troubleshooting of Performance Complaints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–207 Appendix (Hydraulic Schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2–219

DIAGNOSIS 7A2–3

IDENTIFICATION OF TRANSMISSION

7A2–4 DIAGNOSIS

IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)

DIAGNOSIS 7A2–5

SYSTEM DIAGRAM

J1 CONNECTOR (GRAY) J2 CONNECTOR (RED) A OUTPUT SPEED SENSOR

1 5

15

B

16

B–

A TURBINE SPEED SENSOR

13

B

14

29 32

ALDL CONNECTOR ALDL CONNECTOR

A ENGINE SPEED SENSOR

17

B

18 SOL A(PCS)

M 23 3

L

FUSE B+

22 SOL B(PCS)

N 24 P 25

2

31

4

FUSE IGN

C SOL C(ON/OFF) A CHECK TRANS

26 25

SOL D(ON/OFF) B

FUSE IGN

27 RANGE INHIBIT

SOL E(ON/OFF) W SOL F(PWM) LOCKUP

28

23

29

26

J CONTROL UNIT;SPEEDOMETER

S 32

PRESSURE SW T MANIFOLD

16

ENGINE CONTROL MODULE (ECM)

21 7

SWITCH;EXH BRAKE

20

RELAY;EXH CUT (A/T)

13

RELAY;ABS ACTIVE

28

RELAY;ABS ACTIVE

D 1 F 2 E 3 K 4 SUMP TEMP SENSOR

G 10 H 20

TRANSMISSION

AT OIL 24 4A

SWITCH; ECONO MODE

6

4B

RELAY;NEUTRAL

IGN

5

4D

7D

FUSE

7

4C

8

7G

10

7E BACK LAMP

30

7F

6

7C

19 NSBU SWITCH ON TRANSMISSION FUSE IGN

ALDL CONNECTOR SWITCH;PTO RELAY;PTO

Transmission Control Module (TCM) D07M200019

7A2–6 DIAGNOSIS

CIRCUIT DIAGRAM

0.85 BRN/RED

RELAY;PTO

19

RELAY;EXH CUT(ABS) (5) 0.85 PNK FL-251 4

A RELAY; EXH BRAKE(4)

KEY ON

FUSE 6(15A)

0.85 ORN

2

20 0.85 VIO

RELAY;EXH CUT(ABS) (3) 5 3 RELAY ; EXH CUT(A/T) CHECK TRANS FU-18 H-7 0.85 LT GRN 0.85 LT GRN 2 25 49 A/T OIL FU-9 0.85 BLU/YEL 0.85 BLU/YEL 6 24 84 RANGE INHIBIT FU-18 0.85 PNK/GRN 0.85 PNK/GRN 9 61 23 METER

0.85 LT BLU

0.85 PNK/BLK FL-250 5 0.85 BLK

FL-250 10.85 BLU/BLK 4

2

0.85 LT GRN/BLK RELAY;EXH CUT(ABS) (1)

28

0.85 PNK/BLK 13 FU-35

FU-35 0.85 YEL/RED H-7 0.85 YEL/RED 5 8 7 SWITCH;ECONO MODE 0.85 LT GRN/BLK 0.85 LT GRN/BLK 4 RELAY;EXH BRAKE(1) FL-9 FUSE 9(15A) 0.85 PNK FL-9 0.85 BLU 0.85 BLU KEY H-105 ON ECM 17 18 (E56-20) A SWITCH ; COMB 18 (EXHAUST SWITCH) H-6 0.85 BRN/BLU 0.85 BRN/BLU PTO CONN (FB27-3)(PTO SWITCH) 34 FUSE 13(15A) 0.85 BLU/WHT RELAY; 3 BLU 0.85 BLU/WHT IGNITION(1) (KEY ON) 0.85 BLU/WHT S.B.FUSE 6(40A) H-10 3 GRN FUSE 18(15A) 0.85 BLU B+ H-6 46 3 BLK 3 BLK 0.85 BLK 4

0.85 BLK

BATTERY EARTH

10

7

6 2 4

FL-93(J1)CONNECTOR(GRAY)

RELAY;ABS ACTIVE

TCM(Transmission Control Module)(ALLISON 1000 SERIES TM)

RELAY; IGNITION(1) (GND)

FL-251

3 1 5

0.85 VIO/GRN 30 SHIELD

0.5 GRY/BLU

1 2 3 4 5 6 7 8

0.5 BLU

9 10 11 12 13 14 15 16

0.5 PNK

ALDL CONNECTOR(FL-7)

ECM (E56-1) CONTROL UNIT; SPEEDOMETER (FL11-7)

H-106 1

31 29 32

0.85 PNK 16 0.5 WHT 26

D07M200020

DIAGNOSIS 7A2–7

H-10 0.85 GRN H-120 0.85 GRN J-102 5 0.85 GRN/WHT 1 A (Hi) 5 0.85 GRN/WHT 6 0.85 BLU 6 0.85 BLU 2 B (Lo) J-95 23 0.85 BLU/WHT 7 0.85 BLU/WHT 1 A (Hi)

0.85 GRN 15 0.85 GRN/WHT 16 0.85 BLU 13 0.85 BLU/WHT 14 0.85 BRN 17 0.85 BRN/WHT 18

24 0.85 BRN 27 0.85 BRN/WHT

8 0.85 BRN J-101 2 9 0.85 BRN/WHT 1

28

10

0.85 RED/GRN 23 0.85 RED/YEL 22 0.85 VIO/RED 24 0.85 VIO/GRN 25 0.85 YEL

FL-92(J2)CONNECTOR(RED)

TCM(Transmission Control Module)(ALLISON 1000 SERIES TM)

31 0.85 YEL/VIO 26 0.85 YEL/RED

0.85 RED/GRN

0.85 RED/GRN

7 0.85 RED/YEL 14 0.85 VIO/RED 20 0.85 VIO/GRN

11 0.85 RED/YEL 12 0.85 VIO/RED 13 0.85 VIO/GRN

29 0.85 YEL 33 0.85 YEL/VIO

14 0.85 YEL 15 0.85 YEL/VIO

27 0.85 YEL/GRN 28 0.85 RED/WHT

34 0.85 YEL/RED H-4 16 0.85 YEL/RED 37 0.85 YEL/GRN 1 0.85 YEL/GRN 38 0.85 RED/WHT 2 0.85 RED/WHT

29 0.85 RED/BLU 32

39 0.85 RED/BLU 43

3 0.85 RED/BLU 4

0.85 WHT/RED 21 0.85 GRN/WHT 1 0.85 VIO/WHT

0.85 WHT/RED 44 0.85 GRN/WHT 45 0.85 VIO/WHT

0.85 WHT/RED 5 0.85 GRN/WHT 6 0.85 VIO/WHT

2 0.85 BLU/WHT H-6 50 0.85 BLU/WHT 3 0.85 LT GRN/WHT 32 0.85 LT GRN/WHT 4 31

0.85 PNK/WHT 10 0.85 ORN/WHT 20

35

0.85 PNK/WHT

0.85 ORN/WHT

10 0.85 ORN/WHT 11

41

ENGINE SPEED SENSOR

A (Hi)

1

L

8

N

SOL B(PCS)

12 P 14 C SOL C ON/OFF 6 A SOL D ON/OFF 10 B SOL E ON/OFF 15 W SOL F(PWM) LOCKUP 17 J 19 S 3

T

C

18 D

D

F E

20 K

0.85 PNK/WHT

TURBINE SPEED SENSOR

B (Lo)

2 B (Lo) J-105 SOL A(PCS) 4 M

7 0.85 BLU/WHT 5 8 0.85 LT GRN/WHT 2 9

OUTPUT SPEED SENSOR

E R PRESSURE SWITCH MANIFOLD SUMP TEMP SENSOR

9 G(Hi) 13 H(Lo) MAIN TRANSMISSION CONNECTOR

0.85 RED/BLU 5 0.85 BRN/BLU 6 0.85 LT GRN/BLU 7 0.85 PNK/BLU 8 RELAY; NEUTRAL FUSE 9(15A)

RELAY; IGNITION(2)

0.85 RED/BLU J-103 12 4 4A 0.85 BRN/BLU 0.85 BRN/BLU 13 0.85 LT GRN/BLU 0.85 LT GRN/BLU 1 4D 14 0.85 PNK/BLU 2 4B 0.85 PNK/BLU 3 4C 15 0.85 ORN/WHT J-104 H-120 4 7D 0.5 BLU 0.5 BLU 0.85 RED/BLU

48 40 47 54

0.5 RED

1

0.5 RED

5

3

1.25 PNK

2

1.25 PNK

7

7E

1.25 RED

3

1.25 RED

3

7C

6

7F

4

C P

NSBU SWITCH ON TRANSMISSION

BACK LAMP

NOTE; CONNECTOR No. H-10 0.85 GRN FEMALE SIDE CONNECTOR

B

7G

2 H-31 13 4

A

5

WIRE SIZE (mm2) WIRE COLOR

MALE SIDE CONNECTOR TERMINAL No. D07M200002

7A2–8 DIAGNOSIS

ABBREVIATIONS A/N

Assembly Number

ABS

Anti-lock Brake System

Amp

Unit of electrical current.

CAN

Controller Area Network – A network for all SAE J1939 communications in a vehicle (engine, transmission, diagnostics, ABS, etc.)

CT

Closed Throttle

DNA

Does Not Adapt – Adaptive shift control is disabled.

DNS

DO NOT SHIFT – Refers to the DO NOT SHIFT diagnostic response during which the CHECK TRANS light is illuminated and the transmission will not shift and will not respond to the Shift Selector.

DTC

Diagnostic Trouble Code

DVOM

Digital volt/ohmmeter

ECM

Engine Control Module – Available on electronically-controlled engines – provides some relevant data to TCM.

GPI

General Purpose Input – Input signal to the TCM to request a special operating mode or condition.

GPO

General Purpose Output – Output signal from the TCM to control vehicle components (such as PTOs, backup lights, etc.) or allow a special operating mode or condition.

J1939

High-speed vehicle serial data communications link.

LED

Light-Emitting Diode – Electronic device used for illumination.

NNC

Neutral No Clutches – Neutral commanded with no clutches applied.

NSBU Switch

Neutral Start Backup Switch

NVL

Neutral Very Low – The TCM has sensed turbine speed below 150 rpm. This is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. When attained, the C4 and C5 clutches are applied to lock the transmission output.

OBD II

On Board Diagnostics Second generation. EPA mandated specification for vehicle diagnostics.

Ohm

Unit of electrical resistance.

PCCS

Production Calibration Configuration System

PPC

Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is proportional to the current being supplied to the solenoid.

PROM

Programmable Read Only Memory

PSM

Pressure Switch Module – Part of transmission control system located inside the oil pan.

DIAGNOSIS 7A2–9 PTO

Power Takeoff

PWM Solenoid

Pulse Width Modulated Solenoid – Solenoids are controlled by pulse width modulation.

Solenoid control of clutch pressures is based on the solenoid’s duty cycle. Duty cycle is determined by the ratio of solenoid’s on-time to off-time.

RPR

Return to Previous Range – Diagnostic response is which the transmission is commanded to return to previously commanded range.

SOL OFF

All SOLenoids OFF

ST

Scan Tool

TCM

Transmission Control Module (also commonly referred to at the “computer”)

TFT

Transmission Fluid Temperatrure – Data provided by thermistor that is part of the PSM.

TID

TransID – A feature which allows the TCM to know the transmission configuration and provide the corresponding calibration required.

TPS

Throttle Position Sensor – Potentiometer for signaling the position of the engine fuel control lever.

V

Version – Abbreviation used in describing TCM software levels.

VDC

Volts Direct Current (DC)

VIW

Vehicle Interface Wiring – Interfaces TCM programmed input and output functions with the vehicle wiring.

Volt

Unit of electrical force.

VOM

Volt/ohmmeter

WOT

Wide Open Throttle

∞

Infinity – Condition of a circuit with higher resistance than can be measured, effectively an open circuit.

7A2–10 DIAGNOSIS

DIAGNOSIS BY USING SCAN TOOL Data Link Connector (DLC) The provision for communication with the control module is the Data Link Connector (DLC). It is located at the lower left of the instrument panel behind a small square cover.

MFW25ASH000101

2

3

4 5

6

7

Reading Diagnostic Trouble Codes Using A Tech 2 or Other Scan Tool The procedure for reading diagnostic trouble code(s) is to used a diagnostic scan tool. When reading DTC(s), follow instructions supplied by tool manufacturer.

Clearing Diagnostic Trouble Codes IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure. When DTCs are cleared, the Failure Record data which may help diagnose an intermittent fault will also be erased from memory.

To clear Diagnostic Trouble Codes (DTCs), use the diagnostic scan tool “clear DTC information” function.

When clearing DTCs follow instructions supplied by the tool manufacturer.

When a scan tool is not available, DTCs can also be cleared by connect the memory clear switch (Blue) one to two second then disconnect the memory clear switch (Blue).

The DLC is used to connect to a scan tool. Some common uses of the scan tool are listed below: • Identifying stored Diagnostic Trouble Codes (DTCs).

• Clearing DTCs. • Performing output control tests.

• Reading serial data.

1

Verifying Vehicle Repair Verification of vehicle repair will be more comprehensive for vehicles with OBD system diagnostic. Following a repair, the technician should perform the following steps: 1. Review and record the Fail Records for the DTC which has been diagnosed.

2. Clear DTC(s).

3. Operate the vehicle within conditions noted in the Fail Records.

4. Monitor the DTC status information for the specific DTC which has been diagnosed until the diagnostic test associated with that DTC runs.

Following these steps are very important in verifying repairs on OBD systems. Failure to follow these steps could result in unnecessary repairs.

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9 10 11 12 13 14 15 16

056MV041-1

MFW25ASH000201

DIAGNOSIS 7A2–11 Tech 2 Scan Tool From 98 MY, Isuzu Dealer service departments are

recommended to use Tech 2. Refer to Tech 2 scan tool user guide.

1

2

4

3

060M200031

Legend (1) PCMCIA Card (2) Tech-2 Tech 2 Features 1 Tech 2 is a 12 volt system. Do not apply 24 volt.

2. After connecting and/or installing, the Vehicle Communications Interface (VCI) module, PCMCIA card and DLC connector to the Tech 2, connect the tool to the vehicle DLC. 3. Make sure the Tech 2 is powered OFF when removing or installing the PCMCIA card.

4. The PCMCIA card has a capacity of 10 Megabytes which is 10 times greater than the memory of the Tech 1 Mass Storage Cartridge.

5. The Tech 2 has the capability of two snapshots.

6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the handling of the card.

(3) DLC Cable (4) SAE 16/19 Adapter

7. The Tech 2 can plot a graph when replaying a snapshot.

8. Always return to the Main Menu by pressing the EXIT key several times before shutting down.

9. To clear Diagnostic Trouble Codes (DTCs), open Application Menu and press “F1: Clear DTC Info”.

7A2–12 DIAGNOSIS Menu • The following table shows, which functions are used the available equipment versions.

F0:

Diagnostic Trouble Codes F0: DTC Information F1: Clear DTC Information

F1:

Data Display

F2:

Special Functions

F3:

Snapshot

F4:

ID Information MFW25ASH000101

DTC On OBD has two options available in the Tech 2 DTC mode to display the enhanced information available. A description of the new modes, DTC Info and Clear DTC Information. After selecting DTC, the following menu appears: • DTC Info • Clear DTC Information Clear DTC Information To clear Diagnostic Trouble Codes (DTCs), use the diagnostic scan tool “clear DTC information” function.

Tech2 Data Display Use the Tech 2 Data Values only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a properly-running engine may be used for comparison with the engine you are diagnosing. The Tech 2 data values represent values that would be seen on a normally-running engine.

Getting Started • Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (2).

2. Connect the SAE 16/19 adapter (4) to the DLC cable (3).

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

4. Make sure the vehicle starter key is off.

5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.

6. The vehicle starter switch turns on.

7. Verify the Tech 2 power up display.

Press (ENTER) To Continue

060RW009

DIAGNOSIS 7A2–13 Operating Procedure (For example) The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

System Selection Menu (2) 2002

ISUZU

F0 : Powertrain

F0 : Diagnostics F1 : Service Programming System

F1 : Body F2 : Chassis

F2 : View Capture Data (F0:ENTER)

F3 : Tool Options

Vehicle Identification

F4 : Getting Started

Select one of the following (F0:ENTER)

Vehicle Identification Select one of the following Model Year(S)

ISUZU Engine Type (W)

4.3L

V6

(4)

4.8L

L4

L35 Diesel

(A)

5.7L

V8

L31

(3)

7.8L

L6

LG4

(2) 2002

(Select Engine Type) Vehicle Identification Select one of the following (Model year ENTER)

Transmisshion Manual

Vehicle Identification

Automatic

Select one of the following Vehicle Type (S) ISUZU

(Select Automatic) MFW25ALH000201

(Enter) MFW25ALH000101

7A2–14 DIAGNOSIS

DIAGNOSIS 7A2–15

7A2–16 DIAGNOSIS

DIAGNOSIS 7A2–17

7A2–18 DIAGNOSIS

DIAGNOSIS 7A2–19

7A2–20 DIAGNOSIS

DIAGNOSIS 7A2–21

7A2–22 DIAGNOSIS

DIAGNOSIS 7A2–23

7A2–24 DIAGNOSIS

DIAGNOSIS 7A2–25

7A2–26 DIAGNOSIS

DIAGNOSIS 7A2–27

7A2–28 DIAGNOSIS

DIAGNOSIS 7A2–29

7A2–30 DIAGNOSIS

DIAGNOSIS 7A2–31

7A2–32 DIAGNOSIS

DIAGNOSIS 7A2–33

7A2–34 DIAGNOSIS

DIAGNOSIS 7A2–35

7A2–36 DIAGNOSIS

DIAGNOSIS 7A2–37

7A2–38 DIAGNOSIS

DIAGNOSIS 7A2–39

7A2–40 DIAGNOSIS

DIAGNOSIS 7A2–41

7A2–42 DIAGNOSIS

DIAGNOSIS 7A2–43

7A2–44 DIAGNOSIS

DIAGNOSIS 7A2–45

7A2–46 DIAGNOSIS

DIAGNOSIS 7A2–47

7A2–48 DIAGNOSIS

DIAGNOSIS 7A2–49

7A2–50 DIAGNOSIS

DIAGNOSIS 7A2–51

7A2–52 DIAGNOSIS

DIAGNOSIS 7A2–53

7A2–54 DIAGNOSIS

DIAGNOSIS 7A2–55

7A2–56 DIAGNOSIS

DIAGNOSIS 7A2–57

7A2–58 DIAGNOSIS

DIAGNOSIS 7A2–59

7A2–60 DIAGNOSIS

DIAGNOSIS 7A2–61

7A2–62 DIAGNOSIS

DIAGNOSIS 7A2–63

7A2–64 DIAGNOSIS

DIAGNOSIS 7A2–65

7A2–66 DIAGNOSIS

DIAGNOSIS 7A2–67

7A2–68 DIAGNOSIS

DIAGNOSIS 7A2–69

7A2–70 DIAGNOSIS

DIAGNOSIS 7A2–71

7A2–72 DIAGNOSIS

DIAGNOSIS 7A2–73

7A2–74 DIAGNOSIS

DIAGNOSIS 7A2–75

7A2–76 DIAGNOSIS

DIAGNOSIS 7A2–77

7A2–78 DIAGNOSIS

DIAGNOSIS 7A2–79

7A2–80 DIAGNOSIS

DIAGNOSIS 7A2–81

7A2–82 DIAGNOSIS

DIAGNOSIS 7A2–83

7A2–84 DIAGNOSIS

DIAGNOSIS 7A2–85

7A2–86 DIAGNOSIS

DIAGNOSIS 7A2–87

7A2–88 DIAGNOSIS

DIAGNOSIS 7A2–89

7A2–90 DIAGNOSIS

DIAGNOSIS 7A2–91

7A2–92 DIAGNOSIS

DIAGNOSIS 7A2–93

7A2–94 DIAGNOSIS

DIAGNOSIS 7A2–95

7A2–96 DIAGNOSIS

DIAGNOSIS 7A2–97

7A2–98 DIAGNOSIS

DIAGNOSIS 7A2–99

7A2–100 DIAGNOSIS

DIAGNOSIS 7A2–101

7A2–102 DIAGNOSIS

DIAGNOSIS 7A2–103

7A2–104 DIAGNOSIS

DIAGNOSIS 7A2–105

7A2–106 DIAGNOSIS

DIAGNOSIS 7A2–107

7A2–108 DIAGNOSIS

DIAGNOSIS 7A2–109

7A2–110 DIAGNOSIS

DIAGNOSIS 7A2–111

7A2–112 DIAGNOSIS

DIAGNOSIS 7A2–113

7A2–114 DIAGNOSIS

DIAGNOSIS 7A2–115

7A2–116 DIAGNOSIS

DIAGNOSIS 7A2–117

7A2–118 DIAGNOSIS

DIAGNOSIS 7A2–119

7A2–120 DIAGNOSIS

DIAGNOSIS 7A2–121

7A2–122 DIAGNOSIS

DIAGNOSIS 7A2–123

7A2–124 DIAGNOSIS

DIAGNOSIS 7A2–125

7A2–126 DIAGNOSIS

DIAGNOSIS 7A2–127

7A2–128 DIAGNOSIS

DIAGNOSIS 7A2–129

7A2–130 DIAGNOSIS

DIAGNOSIS 7A2–131

7A2–132 DIAGNOSIS

DIAGNOSIS 7A2–133

7A2–134 DIAGNOSIS

DIAGNOSIS 7A2–135

7A2–136 DIAGNOSIS

DIAGNOSIS 7A2–137

7A2–138 DIAGNOSIS

DIAGNOSIS 7A2–139

7A2–140 DIAGNOSIS

DIAGNOSIS 7A2–141

7A2–142 DIAGNOSIS

DIAGNOSIS 7A2–143

7A2–144 DIAGNOSIS

DIAGNOSIS 7A2–145

7A2–146 DIAGNOSIS

DIAGNOSIS 7A2–147

7A2–148 DIAGNOSIS

DIAGNOSIS 7A2–149

7A2–150 DIAGNOSIS

DIAGNOSIS 7A2–151

7A2–152 DIAGNOSIS

DIAGNOSIS 7A2–153

7A2–154 DIAGNOSIS

DIAGNOSIS 7A2–155

7A2–156 DIAGNOSIS

DIAGNOSIS 7A2–157

7A2–158 DIAGNOSIS

DIAGNOSIS 7A2–159

7A2–160 DIAGNOSIS

DIAGNOSIS 7A2–161

7A2–162 DIAGNOSIS

DIAGNOSIS 7A2–163

7A2–164 DIAGNOSIS

DIAGNOSIS 7A2–165

7A2–166 DIAGNOSIS

DIAGNOSIS 7A2–167

7A2–168 DIAGNOSIS

DIAGNOSIS 7A2–169

7A2–170 DIAGNOSIS

DIAGNOSIS 7A2–171

7A2–172 DIAGNOSIS

DIAGNOSIS 7A2–173

7A2–174 DIAGNOSIS

DIAGNOSIS 7A2–175

7A2–176 DIAGNOSIS

DIAGNOSIS 7A2–177

7A2–178 DIAGNOSIS

DIAGNOSIS 7A2–179

7A2–180 DIAGNOSIS

DIAGNOSIS 7A2–181

7A2–182 DIAGNOSIS

DIAGNOSIS 7A2–183

7A2–184 DIAGNOSIS

DIAGNOSIS 7A2–185

7A2–186 DIAGNOSIS

DIAGNOSIS 7A2–187

7A2–188 DIAGNOSIS

DIAGNOSIS 7A2–189

7A2–190 DIAGNOSIS

DIAGNOSIS 7A2–191

7A2–192 DIAGNOSIS

DIAGNOSIS 7A2–193

7A2–194 DIAGNOSIS

DIAGNOSIS 7A2–195

7A2–196 DIAGNOSIS

DIAGNOSIS 7A2–197

7A2–198 DIAGNOSIS

DIAGNOSIS 7A2–199

7A2–200 DIAGNOSIS

DIAGNOSIS 7A2–201

7A2–202 DIAGNOSIS

DIAGNOSIS 7A2–203

7A2–204 DIAGNOSIS

DIAGNOSIS 7A2–205

7A2–206 DIAGNOSIS

DIAGNOSIS 7A2–207

7A2–208 DIAGNOSIS

DIAGNOSIS 7A2–209

7A2–210 DIAGNOSIS

DIAGNOSIS 7A2–211

7A2–212 DIAGNOSIS

DIAGNOSIS 7A2–213

7A2–214 DIAGNOSIS

DIAGNOSIS 7A2–215

7A2–216 DIAGNOSIS

DIAGNOSIS 7A2–217

7A2–218 DIAGNOSIS

DIAGNOSIS 7A2–219

DIAGNOSIS 7A2–220

DIAGNOSIS 7A2–221

DIAGNOSIS 7A2–222

DIAGNOSIS 7A2–223

DIAGNOSIS 7A2–224

DIAGNOSIS 7A2–225