2007 ISUZU KB P190 automatic transmission

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–36
5 If not previously dropped, remove the spring (1).
If required, use snap ring pliers to rotate and pull the
3 – 4 accumulator piston (2) to remove it from the
transmission case. Remove and discard the piston
seal.
Figure 7C4 – 49
6 Remove the check-ball (1) if not previously dropped. Remove the 3rd accumulator check ball assembly (2),
the orifice cup plug (3) and the guide pins (A) from the
transmission case.

Figure 7C4 – 50
Clean and Inspect

To avoid personal injury, wear safety glasses
and gloves when using compressed air and
cleaning fluids.
1 W ash all components in a commercially available cleaning fluid and blow dry using compressed air.
2 Inspect the components for the following:
• piston for porosity,
• ring groove or pin hole damage,
• spring for distortion or damage,
• accumulator bore for wear or damage and
• spacer plate, filter screens and check balls for damage.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–37
Reinstall
1 Lubricate a new seal (1) with petroleum jelly and install
it to the 3 – 4 accumulator piston (2).
2 Reinstall the piston onto the pin (3). The piston side with the three lugs (4) must face out of the bore.
3 Reinstall the 3 – 4 accumulator spring, use a small amount of petroleum jelly to hold it in place, as
needed.

Figure 7C4 – 51

Ensure the guide pins are fully installed with
no thread visible. Otherwise the spacer plate
gasket could be caught in the thread during
installation, resulting in incorrect alignment.
4 Reinstall the guide pins (A) at the correct locations in the transmission case.
5 Reinstall the check ball (1) in the transmission case using a small amount of petroleum jelly to hold it in
place.
6 Reinstall the 3rd accumulator check ball assembly (2) and the orifice cup plug (3) in the transmission case.
Figure 7C4 – 52

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–38
7 If a new spacer plate (1) is installed, it is necessary to
fit two filter screens (2 and 3) to the spacer plate.
Figure 7C4 – 53
NOTE
When installing the spacer plate locate the
gaskets as follows:
• The gasket (2) marked CA is fitted between
the spacer plate and the transmission case.
• The gasket (3) marked VB is fitted between
the spacer plate and the control valve body.
8 Reinstall the spacer plate (1) with the new gaskets (2 and 3) smeared with petroleum jelly. Hold
the spacer plate in place until the 1 – 2 accumulator is
reinstalled.
9 W hile supporting the spacer plate, carefully reinstall the 1 – 2 accumulator assembly (4), refer to
3.12 1 – 2 Accumulator Assembly.
Figure 7C4 – 54

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–39
10 Reinstall the plate (2) supporting the spacer plate and
tighten the three attaching bolts (1) to the correct
torque specification.
Spacer plate support plate attaching
bolt torque specification ..................................... 12.0 Nm
11 Reinstall the control valve body, refer to 3.14 Control Valve Body.
12 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.
13 Lower vehicle to the ground.
14 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid
leaks from the oil pan area, refer to 2.1 Transmission
Fluid.
Figure 7C4 – 55
3.16 Filler Tube and Breather Hose
Remove
NOTE
The breather hose and/or vent pipe can be
removed independently from the filler tube as
described in step 7.

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 6D1-3
Battery, before disconnecting the battery.
1 Disconnect the battery ground lead.
2 Release the lock down lever (1) and remove the transmission fluid level indicator from the filler tube (2).

Figure 7C4 – 56
3 Remove the bolt (1) attaching the filler tube (2) to the side of the right-hand cylinder head, refer to Figure 7C4 – 57.
4 Using a twisting and pulling motion, remove the filler tube from the seal (3) in the transmission case.

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–40
5 Remove the filler tube from the engine compartment.
6 Remove the filler tube seal from the transmission case and discard.
7 If the breather hose needs to be replaced proceed as follows: a unclip the breather hose (4) from the harness channel (5).
b Remove the transmission support and lower the rear of the transmission sufficiently to get access to the breather hose, refer to 3.7 Transmission Support and Mount.
c Disconnect the breather hose from the T-joint (6) and the top of the transmission case and remove.
d If required, remove the two bolts (7) attaching the brackets of the vent pipe (8) to the chassis, disconnect from the T-joint and remove the vent pipe.

Figure 7C4 – 57
Reinstall
Reinstallation of the transmission filler tube and/or the breather hose is the reverse of the removal procedure, noting the
following:
1 Smear a new filler tube seal with clean transmission fluid and fit it to the transmission case.
2 Ensure the transmission breather hose and the harness are secured to the filler tube lower bracket.
3 Tighten the bolt attaching the filler tube bracket to the correct torque specification.
Filler tube bracket attaching bolt
torque specification ................................. 20.0 – 35.0 Nm
4 If required, tighten the two bolts attaching the vent pipe bracket to the chassis to the correct torque specification.
Vent pipe attaching bolt
torque specification ..............................................6.0 Nm

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–41
3.17 Transmission Cooler Line/Hose
Assemblies
Remove
1 Disconnect the transmission cooler hose/line assemblies from the radiator quick connect fittings as
follows:
a Pull back the verifier disc (1) from the quick connect fitting (2) and slide it back along the line.
b Open the release tool, Tool No J-41623-B (3), slip it over the cooler line to be disconnected
from the radiator, ahead of the verifier disc.
c Slide the release tool along the cooler line and engage it with the quick-connect fitting.
d W hile pushing inwards, rotate clockwise the release tool about one sixth of a turn to release
the spring clip holding the cooler line.
e With the release tool held in this position, pull back on the cooler line to release it.
f Plug the openings to prevent fluid loss and/or contamination.
g Repeat the procedure to remove the remaining cooler line.
NOTE
If the spring clip and/or O-ring seal in the quick-
connect fitting is damaged during the removal
process, the complete fitting must be replaced.
2 Unclip the outlet cooler line (4) from the radiator fan shroud (5).
Figure 7C4 – 58
3 Remove the screw (1) attaching the transmission cooler line bracket (2) to the right-hand side of the
engine.

Figure 7C4 – 59
4 Remove the transmission support, refer to 3.7 Transmission Support and Mount.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–42
5 Carefully lower the rear of the transmission sufficiently to get access to the cooler lines.
6 Place a suitable sized drip tray underneath the transmission.
7 W ith the rear of the transmission lowered, disconnect the cooler lines from the transmission, as follows:
a Pull back the verifier disc (1) to release it and slide it back along the cooler line (2).
b Open the release tool, Tool No J-41623-B (3), slip it over the cooler line to be disconnected
from the transmission, ahead of the verifier disc.
c Slide the release tool along the cooler line and engage it with the quick-connect fitting (4).
d W hile pushing inwards, rotate clockwise the release tool about one sixth of a turn to release
the spring clip holding the cooler line.
e With the release tool held in this position, pull back on the cooler line to release it.
f Plug all openings to prevent fluid loss and/or contamination.
g Repeat this process with the remaining cooler line.
NOTE
If the spring clip and/or O-ring seal in the quick-
connect fitting is damaged during the removal
process, the complete fitting must be replaced.
Figure 7C4 – 60
8 Carefully remove the two cooler lines from the vehicle.
9 As required, separate the two cooler lines by removing the bracket and the two clips.
Reinstall
1 On the transmission end, ensure the spring clip and/or O-ring seal in each quick-connect fitting is not damaged, replace the complete fitting if required.
2 If required, fit the bracket and the two clips to attach the transmission two cooler lines together.
3 Position the cooler lines in place, attach the cooler line bracket (2) with the screw (1) hand tight to the right-hand side of the engine, refer to Figure 7C4 – 59.
4 Remove the plugs from the cooler lines and transmission fittings and wipe all exposed parts clean.
5 At the transmission end, smear the fluid lines rear fittings with clean automatic transmission fluid and push the quick-connect fittings together.

If the verifier disc does not clip into place, the
quick-connect fitting is not engaged, rectify
as required.
6 As a security check, push and clip each verification disc into place over the quick-connect fittings. If difficulty is experienced, repeat the installation process until the verification disc can be clipped into place over the
transmission quick-connect fitting.
7 Reinstall the transmission support, refer to 3.7 Transmission Support and Mount.
8 Remove the plugs from the cooler lines and radiator fittings and wipe all exposed parts clean.
9 At the radiator end, smear the fluid lines fittings with clean automatic transmission fluid and push the quick-connect fittings together, refer to Figure 7C4 – 58.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–43

If the verifier disc does not clip into place, the
quick-connect fitting is not engaged, rectify
as required.
10 As a security check, push and clip each verification disc into place over the quick-connect fittings. If difficulty is experienced, repeat the installation process until the verification disc can be clipped into place over the radiator
quick-connect fitting.
11 Snap the outlet cooler line (4) in the clip (5) of the radiator fan shroud.
12 Ensure the routeing of the cooler lines is correct and there is no fouling of the lines.
13 Tighten the screw attaching the cooler lines bracket to the correct torque specifications.
Transmission cooler lines bracket
attaching screw torque specification .................. 23.0 Nm
14 If required, top up the transmission fluid level (cold).
15 Start the engine and check for any fluid leak at the fittings. If a leak is found, stop the engine and rectify the leak.
16 Check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.
3.18 Transmission Assembly
Remove

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 6D1-3
Battery, before disconnecting the battery.
1 Disconnect the battery ground lead.
2 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
3 Remove the heat shield from the neutral start and back-up lamp switch, gently prise the selector cable from the transmission external manual shaft linkage and remove the selector cable from the bracket, refer to
3.3 Selector Cable Assembly.
4 Disconnect the harness connectors from the following:
a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on four wheel drive vehicles (4W D), refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
NOTE
If the battery is connected, avoid turning the
ignition switch to the ON position, as the transfer
case control module (TTCM) must first be
removed (memory to be cleared as Check 4W D
Indicator will light).
5 Remove the following components: a Front and centre exhaust assemblies, refer to 6F Exhaust System.

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ISUZU KB P190 2007