2007 ISUZU KB P190 ECO mode

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–3
1 General Information
This Section describes the removal and reinstallation procedures of the four speed 4L60E hydra-matic automatic
transmission as well as the service operations which can be performed with the transmission still fitted to the vehicle.
1.1 General Service Information
Description
The shift selector mechanism is linked to the transmission manual shaft with a selector cable. A heat protector is fitted
over the neutral start and back-up switch and manual shaft select lever.
For rear wheel drive (RWD) vehicles an extension housing is fitted to the rear of the transmission case.
Four wheel drive (4W D) vehicles have an adaptor housing and transfer case fitted to the rear of the transmission case,
for description and service operation refer to 7D Transfer Case and Adaptor Housing.
The four speed 4L60E hydra-matic automatic transmission is fitted with a filler tube, a breather hose and a vent pipe for
hot fluid overflow.
The transmission fluid is driven through a cooler within the radiator via the cooler line/hose assemblies to maintain
normal operating temperature.
Service Information

Throughout the service operations within this
Section, when handling retaining clips, using
compressed air or cleaning fluids, wear safety
equipment to avoid personal injury.
Refer to 7C1 Automatic Transmission – 4L60E – General Information for the following:
• information relating to mechanical and electrical operations,
• abbreviations, transmission specifications, special tools and torque wrench specifications,
• servicing, cleaning and inspection procedure recommendations.
It is essential to read and understand the General Information, W arnings, Cautions and Service Notes contained in that
same Section, before any service operation is performed on the four speed 4L60E hydra-matic automatic transmission or
any associated components.
Failure to comply with the procedures and service notes can affect the reliable and efficient operation of this automatic
transmission.
1.2 WARNINGS, CAUTIONS and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
GM HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these
instructions.
Definition of WARNING, CAUTION and NOTE Statements
Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. GM HOLDEN LTD is dedicated to the presentation of service information that helps the technician to
diagnose and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard
to the technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–4
WARNING Defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A WARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION Defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE Defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–5
2 Maintenance Operations
2.1 Transmission Fluid
When adding or changing the transmission fluid, use only the recommended automatic transmission fluid, refer to
0B Maintenance and Lubrication.
For the automatic transmission fluid diagnosis, refer to 7C3 Automatic Transmission – 4L60E – Hydraulic and
Mechanical Diagnosis.
Transmission Fluid Colour
New transmission fluid is red in colour due to a dye that is added to the fluid so it can be distinguished from other oils and
lubricants. The red dye is not permanent and as such, is not an indicator of the quality of the fluid.
As the vehicle is driven the transmission fluid will quickly look darker in colour and appear to be a light brown. A dark
brown colour with a distinctively burnt odour may indicate fluid deterioration and the need for fluid replacement.
NOTE
A dark brown fluid colour observed, coupled with
a reported delayed shift pattern may only indicate
that fluid replacement is required. This is not a
definite indication of a potential transmission
failure.
Transmission Fluid Level
NOTE
Carry out this operation with the transmission at
normal operating temperature (82 – 94°C), as the
temperature greatly affects the fluid level.
1 Drive the vehicle for a distance of at least 25 km to bring the transmission up to normal operating temperature.

If the transmission is not at normal operating
temperature and the correct procedure is not
followed, the result could be a false reading of
the fluid level on the transmission fluid
indicator.
2 If the vehicle has been operated under any of the following conditions, switch the engine off and allow the transmission to cool for approximately thirty minutes:
• in high ambient temperatures above 32° C,
• at sustained high speeds,
• in heavy stop / start city traffic during hot weather, or
• towing.
3 Park the vehicle on level ground.
4 Move the gear selector to the Park position and apply the park brake.
5 Allow the engine to idle for 3 minutes with the accessories turned off.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–6
6 Lift the locking lever (1) on the transmission fluid
indicator, then remove the indicator from the filler
tube (2) and check the fluid colour, condition and level.

Do not overfill the transmission. Overfilling
can cause aeration resulting in fluid loss,
shift complaints and possible damage to the
transmission.
7 If the transmission fluid level is low, add only enough of the recommended fluid until
its level shows onto the
crosshatch hot area (3) of the fluid indicator.
Figure 7C4 – 1
2.2 Reverse Flush and Flow Rate Test
It is essential to perform a reverse flush and oil cooler flow rate test after any of the following:
• the transmission is repaired or replaced,
• fluid contamination is suspected, or
• whenever the oil pump and/or torque converter is replaced.
NOTE
The reverse flush must be completed prior to
conducting a flow rate test.
Reverse Flush
1 Disconnect both cooler hose/line assemblies at the transmission and at the radiator cooler, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
2 Check the cooler hose/line to radiator cooler fittings for damage, replace as required.

To avoid personal injury, wear safety glasses
when using compressed air.
3 Carefully check the radiator cooler lower fitting to see if any foreign material is evident at this point. If foreign material is found, remove it with a suitable tool and/or compressed air at a reduced pressure of approximately
345 kPa blown in the reverse direction through the cooler.
4 Using compressed air at a reduced pressure of approximately 345 kPa blown in a reverse direction, clean the cooler hose/line assemblies.
5 Reconnect the cooler outlet line to the transmission and both cooler hose/line assemblies to the radiator cooler fittings, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
NOTE
Do not reconnect the cooler inlet line at the
transmission end. This line needs to be left
disconnected to perform the flow rate test.
6 Perform the flow rate test, refer to Flow Rate Test in this Section.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–7
NOTE
This will also flush the cooler hose/line
assemblies and cooler with transmission fluid.
7 If the flow rate is satisfactory, reconnect the cooler inlet line to the transmission, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
8 Lower the vehicle, check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.
Flow Rate Test

Do not run the engine any longer than
absolutely necessary, as a fluid level too low
can cause aeration and foaming.
1 Ensure the transmission fluid is at the recommended level or slightly above, refer to 2.1 Transmission Fluid.
2 Disconnect the cooler inlet line at the transmission quick-connect fitting, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
3 Place a suitable size container underneath the disconnected cooler inlet line.
4 W ith the selector lever in the P position, start the engine and observe the fluid flow into the container after all the air bubbles have ceased and a steady flow is evident. Measure the flow rate over 20 seconds and ensure it is within
the specification.
Transmission fluid flow rate specification per 20 Seconds:
Temperature: Ambient ............................................................ 0.7 Litres 86° – 93° C ...................................................... 1.2 Litres
5 If the flow rate is less than the specification, the cause of the low flow rate must be located and rectified. Possible cause could include:
• restricted cooler within the radiator tank,
• kinked or damaged transmission cooler hose/line assemblies, or
• internal transmission fault such as a faulty pump.
6 Reinstall the cooler inlet line to the transmission quick-connect fitting, refer to 3.17 Transmission Cooler Line/Hose Assemblies.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–20
9 Install the seal protector, Tool No. AU583-1 (1) into
one of the two plastic seal installers, Tool No.
AU583-2 (2).
NOTE
Two plastic seal installers are required because
of the restricted space between the end of the
manual shaft and the floor pan.
10 Lubricate the lip of a new seal (3) with clean automatic transmission fluid and install it over the seal protector
sleeve, with the steel casing facing the installer tool.
11 Install the seal protector with the new seal and installer tool over the manual shaft (4) and up to the
transmission case.

If the seal protector sleeve jams on the
manual shaft, the flats on the shaft locating
the selector lever will be burred. Use a fine
file to remove any burrs and then proceed.
12 Fit the second plastic seal installer over the manual shaft until it seats against the first installer.
13 Install the manual shaft linkage attaching nut (5) and tighten it to drive the seal in position into the
transmission case.
14 Remove the seal installer and protector tools from the manual shaft.
Figure 7C4 – 18
15 Reinstall the neutral start and back-up lamp switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
16 Lower the vehicle to the ground and as required, check and top up the automatic transmission fluid level, refer to 2.1 Transmission Fluid.
3.7 Transmission Support and Mount
Remove
1 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
2 Support the transmission with a Jack, do not place the support underneath the extension housing or the oil pan, refer to Figure 7C4 – 19.
3 Remove the clip (1) holding the fuel feed and fuel vapour lines on the transmission support (2).
4 Remove the bolt (3) attaching the heat shield (4) to the transmission support.
5 Remove the two nuts (5) attaching the transmission mount to the support.
6 Remove the four bolts and nuts (6) attaching the transmission support to the under body side rails and remove the support.
7 If required, remove the two bolts (7) attaching the transmission mount (8) to the extension housing and remove the mount.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–27

To prevent personal injury, wear safety
glasses when removing the clip.
NOTE
Note the following when removing the solenoid:
• If required, rotate the solenoid until the flat
part of the clip becomes visible.
• The removal is only necessary to access the
TCC solenoid attaching bolts.
4 Using a hooked piece of wire or a small flat blade screwdriver, remove the clip (1) retaining the
TCC PWM solenoid (2).
5 With a twisting and pulling motion remove the TCC PWM solenoid from the control valve body,
remove and discard the O-ring.
Figure 7C4 – 29
6 Remove the two bolts (1) attaching the TCC solenoid assembly (2) to the control valve body.

Figure 7C4 – 30
7 W ithdraw the TCC solenoid assembly (1) from the control valve body (oil pump housing), remove and
discard the O-ring.
8 Lower the harness (2) and TCC solenoid, allow it to hang from the pass-thru connector (3).
9 Remove the control valve body, refer to 3.14 Control Valve Body.
NOTE
This is necessary to provide clearance for the
pass-thru connector to be removed.
Figure 7C4 – 31

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–29
6 Lubricate a new O-ring with petroleum jelly and fit it to
the TCC PW M solenoid (2).
7 Reinstall the TCC PWM solenoid in the control valve body and secure it with the retaining clip (1).
Figure 7C4 – 34
8 Reconnect the control valve body harness connectors. Connectors identification:
• Transmission Fluid Pressure (TFP) Manual
Valve Position Switch (1)
• 1 – 2 Shift Valve Solenoid A (2)
• 2 – 3 Shift Valve Solenoid B (3)
• Pressure Control Solenoid (PCS) (4)
• Torque Converter Clutch Pulse W idth Modulated
(TCC PWM) Solenoid (5)
• 3 – 2 Control Solenoid (6).
Figure 7C4 – 35
9 Secure the harness frame to the control valve body, place the tab between the valve body and pressure
switch in location (1) and press the harness frame in
position on bolt bosses (2 and 3).
Figure 7C4 – 36
10 Reinstall the oil pan and filter and fill the transmission with the recommended automatic transmission fluid, refer to 3.1 Fluid Change and Filter Replacement.
11 Lower vehicle to the ground.

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ISUZU KB P190 2007