2007 ISUZU KB P190 oil

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-117

(3) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication is receiving
enable.
• DTC Clear is not operating.
(4) DTC U2104 is not detecting failure or not deciding failure.
Condition For Setting The DTC
Detection standard is met for 2.5 second continuously.
Detection standard:
If one or more ID sent from Engine Control Module
(ECM) is not completed receiving for 2 basic cycles
since last receiving completion.
Action Taken When The DTC Sets
• Throttle judgment on torque reduction control, line
pressure control at stationary status, line pressure
reduction control at gear change and line pressure
reduction control at garage. (Throttle opening 100%)
• Line pressure FULL output.
• Throttle judgment on gear change control (Throttle
opening 0%).
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control (keep mode).
• No L-up control.
• Control Engine rpm at 7000rpm (No inertia
calculation).
• Control actual torque at MAX.
• Control driver torque at MAX.
• Control engine coolant temperature at 80 °C (176 °F).
• No coast control.
• No 3rd Start mode control.
• No line pressure reduction control at garage.
• No output revolution sensor failure detection.
• No C-0 rev sensor failure detection.
• No selector position switch failure detection.
• No oil temperature sensor failure detection.
• No T/F Hi-Low SW failure detection (Execute T/F
judgment using only T/F-SW ).
• No speed mater signal failure detection.
• No throttle signal failure detection.
• No Engine torque signal failure detection.
• No engine coolant temperature signal failure
detection.
• No Engine revolution signal failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• Cancel engine rpm condition of prerequisite of suppl
y
voltage failure detection.
• Control vehicle speed of speed meter at 0km/h.
• No torque reduction at stall.
• No cruise control.
• No warm up control.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
• The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
• After more than 1 second has elapsed after the ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
• Inspect the wiring for EMI (Electro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check fo
r
improperly installed electrical options. W hen this test
is performed, turn “OFF” on electronic auto parts
switches to improperly for a noise preventing.


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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (AW30–40LE)
TABLE OF CONTENTS

Service Precaution .................................................. 7A3-2
Diagnosis ................................................................. 7A3-3
Basic Troubleshooting ........................................ 7A3-3
Manual Shifting Test ........................................... 7A3-9
Stall Test ............................................................... 7A3-9
Time Lag Test ...................................................... 7A3-10
Hydraulic Test ...................................................... 7A3-11
Road Test ............................................................. 7A3-12
Shift Point Chart and Lock-Up Point Chart ..........7A3-16
Shift Point Chart ................................................... 7A3-16
Lock-Up Point Chart ............................................ 7A3-17
Transmission Fluid Level and Condition ..............7A3-18
Inspection ............................................................. 7A3-18
ATF Replacement ................................................... 7A3-19
Inspection ............................................................. 7A3-19
Neutral Start Switch (Mode Switch) ......................7A3-20
Inspection ............................................................. 7A3-20
Removal ................................................................ 7A3-20
Installation ............................................................. 7A3-20
Brake Signal ............................................................ 7A3-21
Inspection ............................................................. 7A3-21
Input and Output Revolution Sensor ....................7A3-22
Inspection ............................................................. 7A3-22
Power and 3rd Start switch ....................................7A3-22
Inspection ............................................................. 7A3-22
Solenoid .................................................................... 7A3-23
Inspection ............................................................. 7A3-23
ATF Temperature Sensor ......................................7A3-24
Inspection ............................................................. 7A3-24

Select Lever ....................................................... 7A3-25 Remove or Disconnect .......................................7A3-26
Install or Connect ................................................ 7A3-26
Shift Cable .......................................................... 7A3-28 Remove or Disconnect .......................................7A3-28
Install or Connect ................................................ 7A3-29
Torque Specifications ......................................... 7A3-30
Transmission Control Module (TCM) ...................7A3-31
Removal ............................................................... 7A3-31
Installation ............................................................ 7A3-31
Shift Solenoid and Lock-Up Solenoid ..................7A3-32
Removal ............................................................... 7A3-32
Installation ............................................................ 7A3-33
Valve Body Assembly and Pressure Control Solenoid ................................................. 7A3-34
Removal ............................................................... 7A3-34
Installation ............................................................ 7A3-36
Rear Oil Seal (Adapter Housing, 4 ×4) ................. 7A3-37
Removal ............................................................... 7A3-37
Installation ............................................................ 7A3-37
Rear Oil Seal (Extension Housing, 4 ×2) .............. 7A3-38
Removal ............................................................... 7A3-38
Installation ............................................................ 7A3-38
Transmission Assembly .........................................7A3-39
Transmission and Associated Parts .................7A3-39
Removal ............................................................... 7A3-40
Installation ............................................................ 7A3-44
Major Components .............................................. 7A3-49





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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-11
Measure Time Lag
1. Fully apply the parking brake.
2. Start the engine. Check idling speed (A/C OFF).
3. Operate the select lever from “N" to “D" position.
Using a stopwatch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 0.7 seconds
4. In same manner, measure the time lag for “N" →
“R".
Time lag: Less than 1.2 seconds
Evaluation
1. If “N" → “D" time lag is longer than specified:
• Line pressure too low
• Forward clutch malfunction
• No.2 one-way clutch not operating properly
2. If “N" → “R" time lag is longer than specified:
• Line pressure too low
• Direct clutch malfunction
• First and Reverse brake malfunction
3. If both time lag is longer than specified:
• Line pressure too low

Hydraulic Test






RTW 67ALH000201
Preparation
1. W arm up the transmission fluid.
2. Remove the transmission case test plug and mount the hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE: Perform the test at normal operating fluid
temperature (50 – 80 °C or 122 – 176 °F).




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ISUZU KB P190 2007

7A3-12 ON-VEHICLE SERVICE (AW30–40LE)
Measure Line Pressure
1. Fully apply the parking brake and chock the four
wheels.
2. Start the engine and check idling rpm.
3. Select into “D" position, step down strongly on the brake pedal with your left foot and while
manipulating the accelerator pedal with the right
foot, measure the line pressures at the engine
speeds specified in the table.
4. In the same manner, perform the test in “R" position.


Line pressure kPa (kg/cm
2/psi) Engine
speed “D" position “R" position
Idling 349 – 408
(3.6 – 4.2 /51 – 59) 577 – 675
(5.9 – 6.9/84 – 98)
Stall 1,206 – 1,353
(12.3–13.8/175–196) 1,646 – 1,979
(16.8–20.2/239–287)

Evaluation
1. If the measured values at all positions are higher
than specified:
• Pressure control solenoid defective
• Primary regulator valve defective
2. If the measured values at all positions are lowe
r
than specified:
• Primary regulator valve defective
• Oil pump defective
• Pressure control solenoid defective
3. If pressure is low in “D" position only:
• “D" position circuit fluid leakage
4. If pressure is low in “R" position only:
• “R" position circuit fluid leakage
Road Test
NOTE: Perform the test at normal operating fluid
temperature (50 – 80 °C or 122 – 176 °F).
“D" Position Test in “NORMAL", and
“POWER" Pattern
Select into the “D" position and hold the accelerator
pedal constant at the 50% and 100% throttle valve
opening positions.
Push in one of the pattern selector buttons and check
the following:

1. 1–2, 2–3, 3–OD and lock-up, upshifts should take
place, and shift points should conform to those
shown in the automatic shift diagram.


RTW 77ASH003001



RUA37ASH000101



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-19
ATF Replacement
Inspection
NOTE: Do not overfill.
1. Remove the drain plug from oil pan and drain the
fluid.





RUW 17ASH013401
2. Reinstall the drain plug securely.
Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅
⋅⋅
⋅
m/14 Ib ⋅
⋅⋅
⋅
ft)
3. W ith the engine OFF, add new fluid through the fille
r
tube.



Drain and refill 5.2 liter
Dry fill 8.7 liter
Fluid Exxon Mobil ATF-3309
4. Start the engine and shift the selector into all
position from “P" through “L", and then shift into “P".
5. W ith the engine idling, check the fluid level. Add fluid up to the “COLD" level on the dipstick.
6. The ATF level must be checked again for correct level with the “HOT" level.
NOTE: To prevent fluid leaks, the drain plug gasket
must be replaced each time this plug is removed.



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-23
Solenoid
Inspection
1. Resistance check
• Using an ohmmeter, check the resistance
between each terminal (S1/S2/SL) and body.
Solenoid S1, S2 and lock-up solenoid SL
resistance:
11 – 15
Ω
ΩΩ
Ω (at 20°
°°
°C or 68
°
°°
°
F)
(Reference) 12 – 16
Ω
ΩΩ
Ω (at 40°
°°
°C or 104
°
°°
°
F)
• Using an ohmmeter, check the resistance
between each terminal (STH) and (STHG).
Pressure control solenoid resistance:
5 – 5.6
Ω
ΩΩ
Ω (at 20°
°°
°C or 68
°
°°
°
F)
(Reference) 5.4– 6.1
Ω
ΩΩ
Ω (at 40°
°°
°C or 104
°
°°
°
F)




220L100001
NOTE: If the pressure control solenoid resistance is not
within specification, replace the valve body assembly.



2. Operation check
Check the solenoid operation by blowing into an oil
hole as shown in the figure.
Solenoid S1 and S2 (Normal close type)


W hen battery terminal is disconnected No air leaks
W hen battery terminal is
connected Air passes through

Lock-up solenoid SL (Normal open type)


W hen battery terminal is disconnected Air passes through
W hen battery terminal is
connected No air leaks






244RX00001




244RY00005

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ISUZU KB P190 2007

7A3-32 ON-VEHICLE SERVICE (AW30–40LE)
Shift Solenoid and Lock-Up Solenoid
Removal
Preparation:
• Disconnect negative (–) battery cable.
• Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove oil lever gage and oil filler tube.
2. Support transfer case (4
×4) or rear cover (4×2)
with a transmission jack.
3. Remove engine rear mounting nuts.


F07RW 008
4. Remove fule pipe heat protector on tansmission
corssmenber.
5. Remove fuel pipe from the crossmenber.
6. Remove transmission crossmenber.
7. Remove the nineteen bolts.
8. Remove oil pan, using seal cutter 5-8840-2153-0.





RUW 37ASH002901
NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: 5-8840-2153-0
Examine particles in oil pan
Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type o
f
wear you will find in the transmission:
Steel (magnetic) .................. bearing, gear and
clutch plate wear
Brass (non-magnetic).......... bushing wear




240RY00008
9. Remove the oil strainer assembly.




244RY00003

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ISUZU KB P190 2007

7A3-34 ON-VEHICLE SERVICE (AW30–40LE)
Valve Body Assembly and Pressure Control Solenoid






244RY00009
Removal
Preparation:
• Disconnect negative (–) battery cable.
• Drain the fluid. Refer to ATF REPLACEMENT in this section.
1. Remove the nineteen bolts and oil pan.



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ISUZU KB P190 2007