2007 ISUZU KB P190 sensor

ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ................................................................................................................... ... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................ 7A3 – 2
ATF Level ..................................................................................................................... .... 7A3 – 2
ATF Change .................................................................................................................... . 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 5
Inhibitor Switch .............................................................................................................. . 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ............................................................................................................... 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever .................................................................................................................. ... 7A3 –10
Shift Cable ................................................................................................................... .... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –1 8
Flushing the Transmission Fluid Cooler and Line ...................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20
Special Service Tool ....................................................................................................... 7A 3 –23



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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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

7A3-16 ON-VEHICLE SERVICE (JR405E)
SOLENOIDS, OIL PRESSURE SWITCH AND OIL TEMPERATURE
SENSOR
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure switch connector (wire color: W hite)
4. Low and reverse brake duty solenoid connector
(wire color: Pink and W hite)
5. High clutch duty solenoid connector
(wire color: Green and Gray)

6. Lock-up duty solenoid connector
(wire color: Yellow and Black)
7. 2-4 brake duty solenoid connector
(wire color: Blue and Brown)
8. Low clutch duty solenoid connector
(wire color: Orange and Black)
9. Line pressure solenoid connector
(wire color: Pink)




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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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) 7A4-3
Disassembly steps
1. Torque converter
• Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.
• Drain the ATF from the torque converter.


01ASSY101

2. Turbine sensor and speed sensor
• Remove the turbine sensor from the transmission case.



02ASSY103

•
Remove the speed sensor from the transmission case.



03ASSY106

3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.



240L300002

4. Oil pan
• Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0
• Remove the drain plug from the oil pan and drain the
ATF from the oil pan.
• Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.
• Rotate the automatic transmission so that the oil pan is
facing up.
• Remove the 19 bolts and the oil pan.

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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-27

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter
(mm / in) Linear
diameter
(mm / in) Number of
coils
14 Pressure relief 49.0 / 1.929 7.6 / 0.299 1.1 / 0.043 17.3
15 Pressure regulator 30.5 / 1.201 14.0 / 0.551 1.4 / 0.055 5.7
16 Low and reverse brake fail (A) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
17 Fail 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
18 Low and reverse brake amp 19.5 / 0.768 7.9 / 0.311 0.5 / 0.020 6.9
19 2 – 4 brake fail (A) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
20 Low clutch amp (B) 26.0 / 1.024 11.0 / 0.433 0.5 / 0.020 6.9
21
Torque converter relief More than 47.2
/ 1.858 9.2 / 0.362 1.6 / 0.063 20.2
22 2 – 4 brake solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
23 High clutch accumulator
51.0 / 2.008 6.5 / 0.256 0.8 / 0.031 23.5

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.






244L300011

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)


Solenoids
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)

Reassembly steps
• Coat the parts with ATF before installing them.
• Install the control valve to the control valve lower body.
• Install the oil filter to the control valve lower body.



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ISUZU KB P190 2007