2007 ISUZU KB P190 length

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

UNIT REPAIR (JR405E) 7A4-5

244L300001

•
Remove the 12 bolts and the control valve assembly.

Number of bolts Length
10 (A)
2 (B) 40 mm (1.57 in)
30 mm (1.18 in)



42ASSY118

NOTE:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the valve
from turning).


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ISUZU KB P190 2007

7A4-14 UNIT REPAIR (JR405E)
Number Length (Color)
Control valve rocket
bolts and nuts (A) 2 (Plus 2 nuts) 50 mm (1.97 in) (Gold)
Upper body and
lower body fixing
bolts
(B) 2 45 mm (1.77 in) (Silver)
(C) 13 35 mm (1.38 in) (Silver)
Line pressure
solenoid fixing bolt
(D) 1 16 mm (0.63 in) (Gold)











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7A4-16 UNIT REPAIR (JR405E)

12CV19

4. Solenoid
5. Oil pressure switch • Install the O-rings to each of the solenoids.
• Install the 6 solenoids together and the 3 oil pressure
switches.
NOTE:
Be sure the high clutch oil pressure switch is marked.
• Tighten the bolts to the specified torque.
Torque:
Oil pressure switch bolts – 4 N ⋅
⋅⋅
⋅
m (0.4 kgf ⋅
⋅⋅
⋅
m/35 Ib ⋅
⋅⋅
⋅
in)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) – 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
6. Solenoid fixing plate
7. Harness bracket Install the solenoid fixing plate together with the harness
bracket.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Solenoid fixing plate bolt
(A) 4 16 mm (0.63 in) (Gold)
(B) 7 45 mm (1.77 in) (Silver)

13CV20




14CV21



15CV26

8. Harness assembly
Install the harness assembly.


















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UNIT REPAIR (JR405E) 7A4-17
9. Oil strainer Install the oil strainer.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Oil strainer bolt
(C) 9 13 mm (0.51 in) (Silver)
(D) 4 45 mm (1.77 in) (Silver)

16CV40




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UNIT REPAIR (JR405E) 7A4-21
No. Valve
nomenclature Diameter
(mm / in) Length
(mm / in) Configuration
1 Manual 12.0 /
0.472 82.0 /
3.228
2 2 – 4 brake
accumulator 15.0 /
0.591 37.5 /
1.476
3 Low and reverse
brake fail (B) 10.0 /
0.394 52.0 /
2.047
4 Reverse stall 8.0 /
0.315 50.0 /
1.969
5 Low and reverse
brake solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
6 Pilot 12.0 /
0.472 38.5 /
1.516
7 Low clutch
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
8 Low clutch amp
(A) 12.0 /
0.472 53.5 /
2.106
9 2 – 4 brake fail
(B) 10.0 /
0.394 39.0 /
1.535
10 Lock-up control 12.9 /
0.508 57.5 /
2.264
11 2 – 4 brake amp 12.0 /
0.472 53.5 /
2.106

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7A4-22 UNIT REPAIR (JR405E)
12 High clutch amp 12.0 /
0.472 53.5 /
2.106
13 High clutch
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter (mm / in) Linear
diameter (mm / in) Number of
coils
1 Manual ---- ---- ---- ----
2 2 – 4 brake accumulator 43.9 / 1.728 11.0 / 0.433 2.0 / 0.079 13.1
3 Low and reverse brake fail (B) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
4 Reverse stall 31.5 / 1.240 7.0 / 0.276 1.0 / 0.039 12.8
5 Low and reverse solenoid brake
accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
6 Pilot
32.0 / 1.260 11.0 / 0.433 1.3 / 0.051 9.2
7 Low clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
8 Low clutch amp (A) 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
9 2 – 4 brake fail (B) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
10 Lock-up control 27.0 / 1.063 14.0 / 0.551 1.1 / 0.043 5.7
11 2 – 4 brake amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
12 High clutch amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
13 High clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
Reassembly steps
• Coat the parts with ATF before installing them.
• Install the control valve to the upper body.
• Install the 11 steel balls and springs to the upper body.



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7A4-26 UNIT REPAIR (JR405E)
No. Valve
nomenclature Diameter
(mm / in) Length
(mm / in) Configuration
14 Pressure relief ---- ----

15 Pressure
regulator 16.0 /
0.630 89.5 /
3.524
16 Low and reverse
brake fail (A) 10.0 /
0.394 52.0 /
2.047
17 Fail 12.0 /
0.472 53.5 /
2.106
18 Low and reverse
brake amp 12.0 /
0.472 55.5 /
2.185
19 2 – 4 brake fail
(A) 10.0 /
0.394 65.5 /
2.579
20 Low clutch amp
(B) 12.0 /
0.472 53.0 /
2.087
21 Torque
converter relief 10.0 /
0.394 37.4 /
1.472
22 2 – 4 brake
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
23 High clutch
accumulator 10.0 /
0.394 31.0 /
1.220














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ISUZU KB P190 2007