2007 ISUZU KB P190 torque

7A3-6 ON-VEHICLE SERVICE (JR405E)
INHIBITOR SWITCH
The inhibitor switch is attached to the right side of the
transmission.

Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Disconnect the harness connectors.
4. Use an ohmmeter to check the inhibitor switch continuity between the following terminals as shown
in the figure.
5. Place the select lever in the “N” position.
249R300001
6. Move the select lever to either side.
Check the inhibitor switch continuity between the terminals shown in Step 4.
The continuity readings should remain fairly stead
y
as the select lever is moved.
If there is no continuity or the continuity is intermittent, the inhibitor switch must be adjusted.

Adjust
1. Disconnect the shift cable from the lever.
2. Loosen the inhibitor switch bolts.
3. Use the inhibitor switch set plate to align the neutral holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inibitor switch is not correctly adjusted, the
automatic transmission will not function normally.



4. Tighten the 2 inhibitor switch bolts to the specified
touque.
Torque: 6 N·m (0.6 kgf·m/52 lb·in)
47INH-SW 01
5. Remove the inhibitor switch set plate.
6. Connect the shift cable to the lever.
7. Connect the harness connector.

Remove or Disconnect
1. Remove the cable bracket (1) from the transmission.
2. Disconnect the shift cable (2) from the lever (3).
3. Disconnect the harness connectors.
4. Remove the inhibitor switch bolts.
5. Remove the inhibitor switch (4) from the transmission.

238R300001



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-7
Install or Connect
1. Install the inhibitor switch to the transmission.
Temporarily tighten the inhibitor switch bolts.
2. Move the manual shaft select lever to the “N” position.

249R300002
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
4. Tighten the 2 inhibitor switch bolts to the specified torque.
Torque: 6 N·m (0.6 kgf·m/52 lb·in)
47INH-SW 01
5. Remove the inhibitor switch set plate.
6. Install the cable bracket to the transmission.
7. Connect the shift cable to the lever.
8. Connect the harness connector.
9. Connect the negative battery cable.
10. Remove the wheel blocks.



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ISUZU KB P190 2007

7A3-8 ON-VEHICLE SERVICE (JR405E)
SPEED SENSOR
The speed sensor is attached to the right side of the
transmission.
240L300001
Legend
1. Inhibitor switch
2. Speed sensor
3. Turbine sensor


Inspect
1. During driving at a speed of 20km/h (12mph) with “L”
range in low gear, measure the voltage between the
TCM connector terminals (B13) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)






RTW 47ASH000801
2. If the voltage is outside of the standard value, check
the speed sensor pole piece for the presence o
f
foreign materials and the speeed sensor cable for a
short or open circuit.
If the result of the inspection is normal, replace the speed sensor.
Torque: 6 N·m (0.6 kgf·m/52 lb·in)



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ON-VEHICLE SERVICE (JR405E) 7A3-9
TURBINE SENSOR
The turbine sensor is attached to the right side of the
transmission.

Inspect
1. During driving at a speed of 20km/h (12mph) with “L” range in low gear, measure the voltage between the
TCM connector terminals (B3) and (B5) with a digital
voltmeter.
Standard voltage : approx. 7V (AC range)
2. If the voltage is outside of the standard value, check the turbine sensor pole piece for presence of foreign
materials and the turbine sensor cable for a short o
r
open circuit.
If the result of the inspection is abnormal, replace the turbine sensor.
Torque: 6 N·m (0.6 kgf·m/52 lb·in)



POWER AND 3RD START SWITCH
Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Pry out the switch from the floor console.
4. Disconnect the harness connector.
5. Check continuity between terminals (5) and (6) at third (3rd) position.
6. Check continuity between terminals (3) and (6) at power (PW R) position.
7. Replace the power and 3rd start switch if the result o
f
inspection is abnormal.
8. Connect the harness connector.
9. Connect the negative battery cable.
10. Remove the wheel blocks.
238R300003



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7A3-12 ON-VEHICLE SERVICE (JR405E)
4. Install the spring plate.
a. Insert the detent pin into the base plate detent groove until it touches the front wall (leve
r
assembly in N position).
RTW 37ASH001001
b. Stack the short spring plate and tighten thescrews to the specified torque.


Screw torque 2 N ⋅m (0.2kgf ⋅m/17 lb ⋅in)
c. Check that the detent pin moves smoothly in the
detent groove (shift knob temporarily installed).
5. Temporarily install the sleeve.
6. Move the lever to the “P” position.
7. Adjust the clearance (2) between the detent plate and the pin by moving the select lever knob sleeve
(1).
Detent plate and pin clearance mm(in
)
0.2 - 1.0 (0.01 - 0.04)




255R300002
8. Install the lamp assembly to the lamp socket.
a.
Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b. Insert the lamp assembly into the lamp socket and rotate it 90 degrees clockwise.
9. Remove the sleeve and move the lever to the “N” position.
10. Install the upper housing. Make sure that the 4 latched fasteners are securely closed.
11. Attach the harness connectors to the base plate.
12. Install the sleeve (rotate the sleeve clockwise the same number of turns it was rotated
counterclockwise at disassembly).
13. Install the knob, the knob button, and the knob spring.
14. Install the 2 screws securing the knob and tighten them to the specified torque.
Screw torque: 2 N ⋅m (0.2kgf ⋅m/17 lb ⋅in)








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ON-VEHICLE SERVICE (JR405E) 7A3-15
Torque Specifications
∗
∗∗
∗
N ⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
in)
N ⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)




RTW 77ALF000401

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ON-VEHICLE SERVICE (JR405E) 7A3-17
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Drain the fluid.
Refer to “ATF CHANGE” in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign material, the oil strainer must be replaced.
Further inspection is required to determine the source of the foreign material.
6. Remove the harness assembly (including the oil temperature sensor).
7. Remove the 11 bolts and the solenoid fixing plate.
8. Remove the 6 solenoids and 3 oil pressure switches.

Inspect
Oil pressure switch
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the oil pressure switch to check the oil pressure switch
continuity between the connector and screw.
Replace the oil pressure switch if the result of inspection
is abnormal.

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between
harness terminals 7 and 6 (ground).
Oil temperature sensor resistance:
2,400~2,600 ohms (20 °
°°
°
C)
244L300011

Solenoid
Measure the resistance of each solenoid.
Resistance:
Brown connector – 3.0~3.4 ohms (20 °
°°
°
C)
Gray connector – 12.0~13.2 ohms (20 °
°°
°
C)
White connector – 12.2~13.4 ohms (20 °
°°
°
C)
Replace the solenoid if the result of inspection is
abnormal.

Install or connect
1. Install the O-rings to each of the solenoids.
2. Install the 6 solenoids and 3 oil pressure switches.
Line pressure solenoid bolt torque:
8 N·m (0.8 kgf·m/69 lb·in)
Oil pressure switch bolt torque:
4 N·m (0.4 kgf·m/35 lb·in)
3. Install the solenoid fixing plate together with the harness brackets.
Number Length (Color)
Solenoid fixing plate bolt
(A)
(B)
4
7
16 mm (0.63 in) (Gold)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
4. Install the harness assembly.
5. If removed, install the oil strainer.
Number Length (Color)
Oil strainer bolt
(C)
(D)
9
4
13 mm (0.51 in) (Silver)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
7. Fill the fluid.
Refer to “ATF CHANGE” in this section.
8. Connect the negative battery cable.
9. Remove the wheel blocks.

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ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12 fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Fill with the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. W hen an abnormal amount of debris is found.
2. W hen an abnormal wear or chips on gears and shafts is found while overhauling.
3. W hen there is abnormal clutch facing wear and oil contamination found.

Procedures
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with suitable safet
y
stands.
4. Disconnect the fluid cooler lines at the transmission case and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using solvent and compressed air.
Note:
DO NOT exceed (200 kPa/2.0 kgf/cm
2/28 psi) air
pressure, or damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (4.5 kgf·m/33 lb·ft)
8. Replenish the ATF.
9. Start the engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all the debris from the fluid cooler circuit.
Move the select lever through the various ranges and return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF must be added.
10. Connect the negative battery cable.
11. Remove the safety stands.
12. Remove the wheel blocks.

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ISUZU KB P190 2007