2007 ISUZU KB P190 automatic transmission

Automatic Transmission – 4L60E – General Information Page 7C1–5
Clean and Inspect

Do not use solvents on neoprene seals,
composition faced clutch plates or thrust
washers as damage to parts may occur.
After complete disassembly of a component, wash all metal parts in a clean solvent and dry with compressed air. Blow
oil passages out and check to make sure they are not obstructed, small passages should be checked with tag wire. All
parts should be inspected to determine if replacement is required.
Pay particular attention to the following:
• Inspect linkage and pivot points for excessive wear.
• Bearing and thrust surfaces of all parts should be checked for excessive wear and scoring.
• Check for broken seal rings, damaged ring lands and damaged threads.
• Inspect seals for damage.
• Mating surfaces of castings should be checked for burrs. Irregularities may be removed by lapping the surface with
emery paper laid on a flat surface, such as a piece of plate glass.
• Castings should be checked for cracks and porosity.
1.3 7C2 Automatic Transmission – 4L60E –
Electrical Diagnosis
For transmissions fitted to V6 engines, the electrical diagnosis is in this Section. A new electrical circuit and control
module has been introduced for automatic transmissions fitted to the V6 engines.
1.4 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical Diagnosis
Information contained in 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical Diagnosis will assist in the
diagnosis of the mechanical and hydraulic components in the 4L60E automatic transmission, while the transmission
remains installed on the vehicle.
Examples of the type of diagnostic information contained within this section are:
• transmission functional test,
• line pressure information,
• transmission fluid diagnosis,
• symptom diagnosis and
• shift speed charts.
1.5 7C4 Automatic Transmission – 4L60E –
On-vehicle Servicing
Information in 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing covers transmission fluid level checking, as
well as specific information for servicing some components while the transmission remains installed on the vehicle. This
Section also covers the transmission removal and reinstallation to the vehicle.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–6
2 General information
The hydra-matic 4L60E automatic transmission is fitted to vehicles with HFV6 engine. The mechanical and internal
electrical operation of the transmission unit is controlled by the transmission control module (TCM) for HFV6 engine.
• For information on the mechanical operation of the transmission, refer to General Motors Powertrain Group
Electronically Controlled Automatic Transmission Technician's Guide.
• For further information on the TCM, refer to 3.1 Transmission Control Module.
2.1 Transmission Control Module – HFV6
Vehicles fitted with a V6 engine and the 4L60E transmission have a new control module and data bus architecture from
previous models. This is due to the introduction of the new V6 engine. Mechanically, the transmission has not changed.
V6 equipped vehicles are now fitted with T42 – Delphi with GMPT software, transmission control module (TCM) to
control all transmission operations. For further information on the TCM and its operation, refer to 3 Transmission Control
Module Operation Overview.
2.2 Transmission Identification
The 4L60E automatic transmission application and identification can be determined from the stamping at the rear of the
transmission , in the location (7) as shown in Figure 7C1 – 1.
Identification is as follows:
(1) model year,
• (6 = 2006).

(2) Broad Cast Code Identifier,
• HHD = RWD – 3.6 litre HFV6
• HLD = 4WD – 3.6 litre HFV6
(D = model 4L60E).

(3) Manufacturer Source Code,
• (4 = Ramos).

(4) Julian date (day of the year).

(5) Shift Build,
• 'A','B','J' = First shift,
• 'C','H','W' = Second shift.

(6) Individual transmission serial number.

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Automatic Transmission – 4L60E – General Information Page 7C1–7

Figure 7C1 – 1
Legend
1 Model year
2 Broad Cast Code Identifier
3 Manufacturer Source Code 4 Julian Date
5 Shift Build 6 Individual Transmission Serial Number
7 Identification Stamping Location
2.3 Economy, Power and Cruise Modes
The programming in the transmission control module (TCM) allows for different shift patterns, which are driver
controllable through the use of the power (PWR) button. The power button is located in the centre console.
Economy Mode
The calibration for this mode is for maximum comfort, with minimal intrusion of engine noise and smooth shifts under all
driving conditions. When additional power is required for acceleration, full throttle upshifts are similar to those calibrated
for the power mode.
Power Mode
When activated, the TCM modifies the transmission calibration in the following ways:
1 When the throttle is less than 80% open, later upshift points are provided.
2 Shift time is reduced.
3 The torque converter clutch (TCC) will be applied in both the third and fourth speed ranges.
Cruise Mode
When the driver activates the cruise control (where fitted), the power icon in the instrument clusters multi-function display
(MFD) will be deactivated (provided the vehicle was operating in power mode) and the transmission shift pattern will
switch to the cruise control pattern. When in this mode, the TCM modifies the shift pattern so that earlier downshift and
later upshift points are provided.
Through the electronic programming of the logic processes contained in the TCM, the frequency of gear shifting and
torque converter clutch application and release is minimised. The end result of these logic processes, is that a quick
series of upshifts and downshifts (e.g. a '4 – 3 – 4' shift pattern) is minimised.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–8
2.4 System Protection Devices
Should 1st gear be selected and left in that range, the TCM will protect the engine from an over-speeding condition by
upshifting to 2nd gear at a pre-determined point. Similarly, the TCM provides high speed, downshift protection by
preventing a manual shift into 1st gear above pre-determined engine speeds.
Under severe operating conditions such as towing in high ambient temperatures, fluid temperatures can rise to a point
where lubrication breakdown can occur. In addition to having an oil cooler fitted to the vehicle, the 4L60E transmission is
also fitted with a transmission fluid temperature sensor located in the Transmission Range (TR) Pressure Switch
Assembly (PSA).
When fluid temperatures in excess of 135 °C are sensed, the torque converter clutch is applied as programmed, in 3rd or
4th gear. This action reduces further the fluid temperature during normal operation of the torque converter. While these
high fluid temperatures are sensed however, torque converter clutch apply is not available when the throttle opening is
above 50%.
Similarly, when the fluid temperature is below 29 °C, the TCM prevents torque converter clutch apply.
If a condition occurs, preventing electronic control of the transmission's functions, a 'Fail Safe' mode will default the
transmission to 3rd gear when either Drive or 3 is selected, applying also maximum line pressure. W hile in this mode, the
vehicle operator can still manually select 2, 1, Reverse, Park or Neutral, should the need arise.
2.5 Self Diagnosis
If any transmission operation controlled by the TCM begins to operate outside its pre-set parameters, the TCM has the
ability to store a range of diagnostic codes which can be accessed by the servicing technician, thereby localising the
problem.
2.6 TCM Sensors and Actuators
As indicated earlier, there are a number of sensors and switches providing input information for the TCM programming
that will allow the TCM to change the shift pattern, shift feel and torque converter clutch operation.
The TCM does this by comparing this input information with its predetermined values on shift pattern, fluid pressure
maps, shift duration parameters, extreme heat protection programming and adaptive controls.
In addition, each input signal and output actuator operation is also monitored and if outside its pre-set parameters, a
diagnostic code is logged for future reference by the servicing technician.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–9
3 Transmission Control Module
Operation Overview
3.1 Transmission Control Module
W ith the introduction of the new HFV6 engine, the powertrain architecture has been redesigned to accommodate this
introduction. W ith this design, a new bus architecture and protocol has also been introduced. The new bus connects the
following modules:
• engine control module (ECM),
• transmission control module (TCM),
• powertrain interface module (PIM) and
• ABS module.
The protocol used to communicate between these modules is called General Motors Local Area Network (GM LAN)
which is based on Controller Area Network (CAN) communication protocol. For further information on GM LAN protocol
and data bus structure, refer to 6E1 Powertrain Interface Module – V6.
Component Location
The TCM (1) is located under the instrument panel, it is attached to a bracket mounted to the firewall as shown in
Figure 7C1 – 2.
For the other components using the GM LAN databus, refer to 6E1 Powertrain Interface Module – V6.

Figure 7C1 – 2
Transmission Control Module Data Transfer
The TCM uses various information to control the shift of the transmission. Besides the direct inputs from the various
transmission sensors directly into the TCM, the TCM uses data from the GM LAN databus.
The inputs/outputs directly connected to the TCM from the transmission are:
• shift solenoids,
• torque converter clutch control,
• pressure control solenoid,
• transmission fluid temperature sensor and
• vehicle speed sensor.
Refer to 3.2 TCM Wiring Diagrams.
The transmission also receives inputs from the park/neutral position and back up lamp switch assembly.
The TCM needs other various data parameters to control the transmission correctly. These include throttle plate angle,
whether cruise control is engaged and active or not, engine RPM etc. These are provided to the TCM from the ECM via
serial data using GM LAN communication protocol.
The TCM also supplies information that is used by other components and systems within the vehicle such as the engine
control module (ECM) and instrument cluster. Any information that is required on the body side of the data bus (UART
protocol) is translated by the powertrain interface module (PIM). For further information on the data bus structure, the
PIM and its operation, refer to 6E1 Powertrain Interface Module – V6.

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Automatic Transmission – 4L60E – General Information Page 7C1–10
Transmission Control Module Operation
The TCM processes data every 10 milliseconds from various sensors, such as throttle position, vehicle speed, gear
range, temperature, engine load and other inputs. The TCM compares all its various inputs with the internal programming
and calibration of the TCM using this data, a signal is transmitted to the valve body shift solenoids, which activate the
shift valves for precise shift control. Shift points are therefore precisely controlled and are identical from vehicle to vehic le.
The TCM also control torque converter clutch apply and release.
Shift feel is also electronically controlled by the TCM, by signals sent to the variable force solenoid, which controls fluid
line pressure and it is this pressure that precisely determines how the shifts will feel. In this way, the TCM electronically
synchronises the engine and transmission into a single integrated powertrain system for optimum performance, shift
timing, fuel efficiency and emission control.
3.2 TCM Wiring Diagrams
For details of the transmission control module (TCM) wiring diagrams, refer to 8A Electrical-Body and Chassis.

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Automatic Transmission – 4L60E – General Information Page 7C1–11
4 Transmission Definitions and
Abbreviations
The following definitions and abbreviations are provided to establish a common language and assist the user in
describing transmission related conditions. The use of these terms and/or conditions can be found in the various parts of
the automatic transmission sections, but more particularly in 7C3 Automatic Transmission – 4L60E – Hydraulic and
Mechanical Diagnosis.
4.1 Throttle Position Related Definitions
Throttle Position Definition
Minimum Throttle The least amount of throttle opening required for an upshift.
Light Throttle Approximately 1/4 of accelerator pedal travel (25% Throttle Position).
Medium Throttle Approximately 1/2 of accelerator pedal travel (50% Throttle Position).
Heavy Throttle Approximately 3/4 of accelerator pedal travel (75% Throttle Position).
Wide Open Throttle (WOT) Full travel of the accelerator pedal (100% Throttle Position).
Full Throttle Detent Downshift A quick apply of the accelerator pedal to its full travel, forcing a downshift.
Zero Throttle Coast Down A full release of the accelerator pedal while the car is in motion and in drive range.
Engine Braking A condition where the engine is used to slow the car by manually downshifting
during a zero throttle coast down.
4.2 Noise Condition Related Definitions
Noise Condition Definition
Planetary Gear Noise A whine related to car speed most noticeable in first gear or reverse. Becomes less
noticeable after an upshift.
Pump Noise A high pitch whine increasing with engine r.p.m.
4.3 General Definitions
General Definition
Accumulator A component of the transmission that absorbs hydraulic pressure during the apply of a
clutch or band. Accumulators are designed to control the quality of a shift from one gear range to another.
Adaptive Learning Programming within the TCM that automatically adjusts hydraulic pressures in order to compensate for changes in the transmission (i.e. component wear).
Applied An 'Applied Component' is holding another component to which it is splined or
assembled to. Also referred to as "engaged".
Apply Components Hydraulically operated clutches, servo’s, bands and mechanical one-way roller or
sprag clutches that drive or hold members of a planetary gear set.
Apply Plate A steel clutch plate in a clutch pack, located next to the (apply) piston.
Backing Plate A steel plate in a clutch pack that is usually the last plate in that clutch assembly
(furthest from the clutch piston).
Band An apply component that consists of a flexible strip of steel and friction material that
wraps around a drum. When applied, it tightens around the drum and prevents the drum from rotating.
Brake Switch An electrical device that provides signals to the transmission control module (TCM),
based on the position of the brake pedal. The TCM uses this information to apply or
release the torque converter clutch (TCC).
Centrifugal Force A force that is imparted on an object (due to rotation) that increases as that object moves further away from a centre-point of rotation.

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Automatic Transmission – 4L60E – General Information Page 7C1–12
General Definition
Check Ball A spherical, hydraulically controlled component (usually of steel) that either seals or
opens fluid circuits. It is also referred to as a check valve.
Clutch Pack An assembly of components generally consisting of clutch plates, an apply plate and a
backing plate.
Clutch Plate A hydraulically activated component that has two basic designs: (1) all steel, or (2) a
steel core with friction material bonded to one or two sides of the plate.
Control Valve Body A machined metal casting that contains valve trains and other hydraulically controlled components that shift the transmission.
Coupling Speed The speed at which a vehicle is travelling and no longer requires torque multiplication through the torque converter. At this point, the stator 'free wheels' to allow fluid leaving
the turbine to flow directly to the pump. (Also see Torque Converter).
De-energise(d) To interrupt the electrical current that flows to an electronically controlled device,
making it electrically inoperable.
Direct Drive A condition in a gears set where the input speed and input torque equals the output
speed and output torque. The gear ratio through the gear set is 1:1.
Downshift A change in a gear ratio where both input speed and torque increases.
Duty Cycle In reference to an electronically controlled solenoid, it is the amount of time (expressed
as a percentage) that current flows through the solenoid coil.
Energise(d) To supply a current to an electronically controlled device, enabling it to perform its
designed function.
Engine Compression Braking A condition where compression from the engine is used with the transmission to decrease vehicle speed.
Exhaust The release of fluid pressure from a hydraulic circuit. (The words 'exhausts' and
'exhausting' are also used and have the same intended meaning.)
Fail-safe Mode A condition whereby a component (i.e. engine or transmission) will partially function even if its electrical circuit is disabled.
Fluid In this Section of the Service Manual, 'fluid' refers primarily to automatic transmission
fluid (or ATF) and, for the Hydra-matic 4L60E transmission, the only recommended
fluid is Dexron
III.
Fluid Pressure A pressure that is consistent throughout a given fluid circuit.
Force A measurable effort that is exerted on an object (component).
Freewheeling A condition where power is lost through a driving or holding device (i.e. roller or sprag
clutches).
Friction Material A heat and wear resistant fibrous material, bonded to clutch plates and bands.
Gear A round, toothed device that is used for transmitting torque through other components.
Gear Range A specific speed to torque ratio at which the transmission is operating (i.e. 1st gear,
2nd gear etc.).
Gear Ratio Revolutions of an input gear as compared to the revolutions of an output gear. It can
also be expressed as the number of teeth on a gear as compared to the number of
teeth on a gear that it is in mesh with.
Hydraulic Circuit A fluid passage which often includes the mechanical components in that circuit
designed to perform a specific function.
Input A starting point for torque, revolutions or energy into another component of the
transmission.
Internal Gear The outermost member of a gear set that has gear teeth in constant mesh with the
planetary pinion gears of the gear set.
Land (Valve Land) The larger diameters of a spool valve that contact the valve bore or bushing.

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