By visiting our site, you agree to our privacy policy regarding cookies, tracking statistics, etc. Read more

Isuzu Transmission JR405E Model Workshop Manual

Isuzu

This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift Control: DESC) using a duty cycle type solenoid, which ensures high shift quality. This transmission also controls learning and constantly checks the time of each clutch and brake required for the speed change to match this time with the target value for the optimum speed change.

The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module (TCM). There are four forward speeds and one reverse speed.

The TCM will automatically select the most appropriate shift points and lock-up points depending on the throttle opening angle, the vehicle speed and the vehicle load.

If any trouble arises in the vehicle sensor, throttle sensor, solenoid, etc., the fail-safe control function is activated to keep the running performance. Problems with the sensors, the solenoids can be quickly detected with the self diagnosis procedure described
in this manual.

The JR405E automatic transmission consists of the torque converter, the oil pump, the input shaft, the out put shaft, the planetary gears and the control valve. The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two multiple plate brakes and a one-way clutch.

CONTENTS

  • CONSTRUCTION AND FUNCTION
    • DESCRIPTION
    • STRUCTURE AND FUNCTION OF COMPONENT
    • CONTROL MECHANISM
    • GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION AND HYDRAULIC CIRCUIT
  • DIAGNOSIS
    • BASIC TROUBLE SHOOTING
    • CHECK TRANS INDICATOR & SELF DIAGNOSIS
    • DIAGNOSIS WITH TECH 2
    • TECH 2 CONNECTION
    • TECH 2 OPERATING FLOW CART (START UP)
    • TYPICAL SCAN DATA
    • MISCELLANEOUS TEST
    • INTERMITTENT DIAGNOSIS
    • SNAPSHOT DISPLAY WITH TIS2000 (For Snapshot Data Analysis)
    • SERVICE PROGRAMMING SYSTEM (SPS)
    • CIRCUIT DIAGRAM
    • PARTS LOCATION (1)
    • RHD PARTS LOCATION (2)
    • LHD PARTS LOCATION (3) 4JH1-TC PARTS LOCATION (4)
    • PARTS LOCATION (5)
    • CONNECTOR LIST
    • DIAGNOSIS TROUBLE CODE TABLE
    • FAIL-SAFEFUNCTION
    • DTC P0722 (Flash Code 11) Vehicle Speed Sensor No Signal
    • DTC P0727 (Flash Code 13) Engine Revolution Sensor No Signal
    • DTC P0717 (Flash Code 14) Turbine Speed Sensor No Signal
    • DTC P0710 (Flash Code 15) ATF Temperature Sensor Failure
    • DTC P0560 (Flash Code 16) System Voltage Failure
    • DTC P0705 (Flash Code 17) Inhibitor Switch Failure
    • DTC P1120 (Flash Code 22) Throttle Signal Failure
    • DTC P1875 (Flash Code 25) GND Return Circuit Failure
    • DTC P0753 (Flash Code 31) Low & Reverse Brake Duty Solenoid Failure
    • DTC P0758 (Flash Code 32) 2-4 Brake Duty Solenoid Failure
    • DTC P0763 (Flash Code 33) High Clutch Duty Solenoid Failure
    • DTC P0768 (Flash Code 34) Low Clutch Duty Solenoid Failure
    • DTC P0748 (Flash Code 35) Line Pressure Solenoid Failure
    • DTC P1860 (Flash Code 36) Lock-up Duty Solenoid Failure
    • DTC P1853 (Flash Code 26) Low & Reverse Brake Pressure Switch Failure
    • DTC P1858 (Flash Code 27) 2-4 Brake Pressure Switch Failure
    • DTC P1863 (Flash Code 28) High Clutch Pressure Switch Failure
    • DTC P0731 (Flash Code 41) 1st Gear Ratio Error
    • DTC P0732 (Flash Code 42) 2nd Gear Ratio Error
    • DTC P0733 (Flash Code 43) 3rd Gear Ratio Error
    • DTC P0734 (Flash Code 44) 4th Gear Ratio Error
    • DTC P1750 (Flash Code 51) Low & Reverse Brake Fail-safe Valve Failure
    • DTC P1755 (Flash Code 52) 2-4 Brake Fail-safe Valve Failure
    • DTC P0602 Programming Error
    • SYMPTOM DIAGNOSIS
    • SYMPTOM DIAGNOSIS TABLE
    • No. A1: Vehicle Does Not Run in D, 3, 2, L and R Range
    • No. A2: Vehicle Does Not Run in R Range
    • No. A3: Vehicle Does Not Run in D, 3, 2 and L Range
    • No. B1: Vehicle Runs in N Range
    • No. B2: Poor Acceleration at Starting
    • No. B3: Engine Race Up During Starting (Slip)
    • No. B4: Large Shock When Shift Lever is Changed to N to D Range or N to R Range
    • No. B5: Engine Stalls When Selecting From N Range to R. D. 3. 2 or L Range
    • No. B6: Engine Starter Does Not Run in P or N Range
    • No. B7: Engine Starter Runs Except in P or N Range
    • No. B8: Extended Time Lag When Shift Lever is Changed to N to D
    • No. B9: Extended Time Lag When Shift Lever is Changed to N to R
    • No. B10: Brake is Applied in R Range
    • No. B11: Insufficient Starting or Shaking in D Range
    • No. B12: Noise or Vibration is Generated at Starting
    • No. C1: Engine Race Up (Slip) When Gear is Shifted Up to 1st to 2nd
    • No. C2: Engine Race Up (Slip) When Gear is Shifted Up to 2nd to 3rd
    • No. C3: Engine Race Up (slip) When Gear is Shifted Up to 3rd to 4th
    • No. C4: Engine Race Up (Slip) When Gear is Shift Down or Kick-down to 4th to 3rd
    • No. C5: Engine Race Up (Slip) When Gear is Shift Down or Kick-down to 4th to 2nd
    • No. C6: Engine Race Up (Slip) When Gear is Shift Down or Kick-down to 3rd to 2nd
    • No. C7: Engine Race Up (Slip) When Gear is Shift Down or Kick-down to 4th or 3rd to 1st
    • No. C8: Engine Race Up (Slip) Others
    • No. C9: Barking Feel When Gear is Shifted Up to 1st to 2nd
    • No. C10: Barking Feel When Gear is Shifted Up to 2nd to 3rd
    • No. Cl 1: Barking Feel When Gear is Shifted Up to 3rd to 4th
    • No. C12: Large Shock When Gear is Shifted to 1st to 2nd or 2nd to 1st
    • No. C13: Large Shock When Gear is Shifted to 2nd to 3rd or 3rd to 2nd
    • No. C14: Large Shock When Gear is Shifted to 3rd to 4th or 4th to 3rd
    • No. C15: Large Shock When Kick-down No. C16: Large Shock When No Acceleration
    • No. C17: Large Shock When Gear is Shifted Down to 2nd to 1st in L Range
    • No. C18: Large Shock (Other)
    • No. C19: Large Shock When Vehicle Speed is Downed by No Accelerator Pedal or Vehicle is Stopped
    • No. C20: Large lock-up shock
    • No. C21: Shift Down or Engine Over-run When The Accelerator Pedal is Stepped on in 4th Gear
    • No. D1: Faulty Gear Shifting (Different from Shift Pattern)
    • No. D2: Gear is Shifted Frequently
    • No. D3: Gear Shift Point is Low or High at All Point
    • No. D4: Gear Shift Point is Low or High at Limited Point
    • No. D5: No Kick-down
    • No. E1: No Gearshift
    • No. E2: Only 4th gear (O/D) is Not Selectable
    • No. E3: Gear is Shifted 2nd to 3rd in 2 Range
    • No. E4: Gear is Shifted 1st to 2nd in L Range
    • No. E5: Gear is Shifted 3rd to 4th in 3 Range
    • No. F1: Low Maximum Speed or Poor Acceleration
    • No. F2: Engine Races Up During Acceleration (Slip)
    • No. F3: Noise or Vibration During the Running in R, D, 3, 2 or L Range
    • No. F4: Engine Brake Does Not Apply in L Range
    • No. F5: Engine Stalls Before Vehicle Stops from Running
    • No. G1: Vehicle Moves in P Range or Parking Gear is Not Disengaged other than P Range
    • No. G2: Creep Force is Large
    • No. G3: Creep Force is small
    • No. G4: Large Noise During Idling with the Vehicle in Stop State
    • No. H1: Judder Occurs at the Lock-up
    • No. H2: Large Lock-up Shock
    • No. H3: Lock-up Point is High or Low
    • No. I1: No Lock-up
    • No. J1: Oil Leaks from Breather
    • No. J2: Oil Leaks Between Engine and Converter Housing
    • No. J3: Oil Leaks Between Main Case and Converter Housing
    • No. J4: Oil Leaks Between Main Case and Rear Housing
    • No. J5: Oil Leaks from Oil Pan
    • No. J6: Oil Leaks from Manual Shaft Oil Seal
    • No. J7: Oil Leaks from Oil Cooler Pipe Joint
    • No. Z1: Transmission Overheat
    • No. Z2: Mode Lamp (Power Drive or 3rd Start) Does Not Light Up When The Power Mode or 3rd Start Mode is
    • Turned On
    • No. Z3: Mode Lamp (Power Drive or 3rd Start) Lights Up When The Power Mode or 3rd Start Mode is Turned Off
    • No. Z4: Oil Temperature Warning Lamp Lights up
    • No. Z5: Select Lever Feeling is Faulty.
    • No. Z6: Poor Fuel Consumption
    • No. Z7: Pattern Select Switch is Faulty
    • No. Z8: Oil is Splashed During the Running
    • No. Z9: Abnormal Smell
    • No. Z10: ATF Quantity is Low or High
    • No. Z11: Abnormal Oil Pressure
    • No. Z12: Reverse Buzzer Does Not Ring
    • STALL TEST
    • LINE PRESSURE TEST
    • TIME LAG TEST
    • TEST DRIVE
    • SHIFT POINT CHART
    • SHIFT POINT DIAGRAM
    • TCM VOLTAGE CHECK
  • ON-VEHICLE SERVICE (JR405E)
    • DESCRIPTION
    • AUTOMATIC TRANSMISSION FLUID (ATF)
    • ATF LEVEL
    • ATF CHANGE
    • TRANSMISSION CONTROL MODULE (TCM)
    • THROTTLE POSITION SENSOR
    • INHIBITOR SWITCH
    • SPEED SENSOR
    • TURBINE SENSOR
    • POWER AND 3RD START SWITCH
    • SELECT LEVER
    • SHIFT CABLE
    • SOLENOIDS, OIL PRESSURE SWITCH AND OIL TEMPERATURE SENSOR
    • CONTROL VALVE ASSEMBLY
    • FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
    • TRANSMISSION ASSEMBLY
  • UNIT REPAIR (JR405E)
    • AUTOMATIC TRANSMISSION DISASSEMBLY
    • CONTROL VALVE ASSEMBLY
    • CONTROL VALVE UPPER BODY
    • CONTROL VALVE LOWER BODY
    • OIL PUMP ASSEMBLY
    • CLUTCH PACK (REVERSE AND HIGH CLUTCH ASSEMBLY)
    • CARRIER AND LOW CLUTCH ASSEMBLY
    • TRANSMISSION CASE
    • BEARING AND BEARING RACE INSTALLATION POSITION
    • AUTOMATIC TRANSMISSION REASSEMBLY
    • SERVICE STANDARD
    • SPECIAL SERVICE TOOL

Language: English
Format: PDF
Pages: 320

Isuzu Transmission JR405E Model Workshop Manual PDF free online