2007 ISUZU KB P190 oil

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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-18 ON-VEHICLE SERVICE (JR405E)
CONTROL VALVE ASSEMBLY
244L300001
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. Disconnect the 2 harness connectors leading to the control valve.
7. 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)

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).


BACK TO CHAPTER INDEX
TO MODEL INDEX
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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-1
SECTION 7A4
UNIT REPAIR (JR405E)
TABLE OF CONTENTS
PAGE
Automatic Transmission Disassembly ...................................................................... 7A4- 2
Control Valve Assembly ............................................................................................. 7A4-11
Control Valve Upper Body ......................................................................................... 7A4-18
Control Valve Lower Body ......................................................................................... 7A4-23
Oil Pump Assembly .................................................................................................... 7A4-28
Clutch Pack (Reverse and High Clutch Assembly) ................................................. 7A4-32
Carrier and Low Clutch Assembly ............................................................................ 7A4-41
Transmission Case .................................................................................................... 7A4-54
Bearing and Bearing Race Installation Position ...................................................... 7A4-66
Automatic Transmission Reassembly ...................................................................... 7A4-69
Service Standard ........................................................................................................ 7A4-8 3
Special Service Tool ................................................................................................... 7A4-85




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4-2 UNIT REPAIR (JR405E)
AUTOMATIC TRANSMISSION
DISASSEMBLY
Cleaning the automatic transmission
1. Use compressed steam and /or cleaning oil to thoroughly
clean the outside of the transmission before disassembly.
CAUTION:
Steam under high pressure may cause dirt particles
adhering to the transmission to fly through the air at great
speed. These particles can cause serious eye injury. Wear
protective goggles when steam-cleaning the outside of
the transmission.
2. During disassembly, clean the removed parts with cleaning oil. Dry the parts with compressed air.
Use Compressed air to clean the transmission oil holes
and oil passages.

Automatic transmission disassembly cautions
• Perform the disassembly procedure in a dust-free
environment to prevent the entry of foreign material into
the transmission.
• Inspect each transmission part as you remove it.
• Carefully check the oil pan and the magnet for foreign
material. This is a good way to estimate the transmission
condition.
• Use your bare hands or vinyl gloves to disassemble the
transmission. Do not use ordinary work gloves (loose
threads from the gloves may fall into the transmission and
cause problems).
• Use a plastic hammer to loosen the transmission case
and other aluminum parts during disassembly. Strike
around the parts lightly with the hammer. Do not pry
aluminum parts away from each other with a screwdriver
or similar object.
• Arrange the disassembled parts neatly in the order they
were removed. Cover the parts with a plastic sheet or
similar object to protect them from dust.



BACK TO CHAPTER INDEX
TO MODEL INDEX
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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4-4 UNIT REPAIR (JR405E)

04CV37

•
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 o
f
the foreign material.



45CV29

5. Control valve assembly
• Disconnect the 2 harness connectors leading to the
control valve.




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4-6 UNIT REPAIR (JR405E)

10ASSY116

6. Converter housing
• Position the automatic transmission so that the
converter housing is facing up.
• Remove the 8 bolts and the converter housing.



11ASSY068

7. O-ring
Remove the O-ring from the input shaft.


12ASSY067

8. Oil pump assembly and bearing race
• Remove the 8 bolts.
• Use a slide hammer to remove the oil pump assembl
y
from the transmission case.
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.
• Remove the bearing race from the oil pump assembly.
• Inspect the bearing race surfaces for damage.


14ASSY057

9. Input shaft
Pull the input shaft free.


15ASSY049

10.Clutch pack (Reverse and high clutch assembly) and
bearing
• Pull the clutch pack free.
• Remove the bearing from the clutch pack.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007