2007 ISUZU KB P190 Electrical

Automatic Transmission – 4L60E – General Information Page 7C1–1
7C1
Automatic Transmission – 4L60E –
General Information
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.
1 Section Descriptions ........................................................................................................... ...................3
1.1 WARNINGS, CAUTIONS and NOTES................................................................................................... ................. 3
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 3
WARNING Defined............................................................................................................................................. 3
CAUTION Defined .............................................................................................................................................. 3
NOTE Defined .................................................................................................................................................... 3
1.2 7C1 Automatic Transmission – 4L60E – General Information ....................................................................... .... 4
Recommendations ................................................................................................................................................. 4
Oil Cooler Pipes ..................................................................................................................................................... 4
Clean and Inspect .............................................................................................................. .................................... 5
1.3 7C2 Automatic Transmission – 4L60E – Electrical Diagnosis ...................................................................... ..... 5
1.4 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical Diagnosis ............................................... 5
1.5 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing ...................................................................... .... 5
2 General information ...............................................................................................................................6
2.1 Transmission Control Module – HFV6 ............................................................................................. .................... 6
2.2 Transmission Identification .................................................................................................................................. 6
2.3 Economy, Power and Cruise Modes .................................................................................................................... 7
Economy Mode ...................................................................................................................................................... 7
Power Mode ............................................................................................................................................................ 7
Cruise Mode ........................................................................................................................................................... 7
2.4 System Protection Devices ...................................................................................................... ............................. 8
2.5 Self Diagnosis ........................................................................................................................................................ 8
2.6 TCM Sensors and Actuators ................................................................................................................................. 8
3 Transmission Control Module Operation Overview ...........................................................................9
3.1 Transmission Control Module .............................................................................................................................. 9
Component Location ............................................................................................................. ................................ 9
Transmission Control Module Data Transfer ...................................................................................... ................ 9
Transmission Control Module Operation........................................................................................................... 10
3.2 TCM Wiring Diagrams.......................................................................................................................................... 10
4 Transmission Definitions and Abbreviations ....................................................................................1 1
4.1 Throttle Position Related Definitions ................................................................................................................. 11
4.2 Noise Condition Related Definitions ............................................................................................ ...................... 11
4.3 General Definitions .............................................................................................................................................. 11
4.4 Abbreviations ....................................................................................................................................................... 14
5 Service Notes ........................................................................................................................................15
Fasteners .............................................................................................................................................................. 15
General Workshop Practice ................................................................................................................................ 15
6 Torque Specifications .......................................................................................................... ................16
7 Transmission Specifications.................................................................................................... ...........17

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ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–3
1 Section Descriptions
Service information for the Hydra-matic 4L60E Automatic transmission has been divided into five Sections to assist the
technician to quickly locate the correct service, maintenance and diagnostic information.
The following provides a brief outline of each of the Sections.
• 7C1 Automatic Transmission – 4L60E – General Information
• 7C2 Automatic Transmission – 4L60E – Electrical Diagnosis
• 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical Diagnosis
• 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing
The following provides a brief outline of each of the Sections.
1.1 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.
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 – General Information Page 7C1–4
1.2 7C1 Automatic Transmission – 4L60E –
General Information
This section provides general information about the automatic transmission, including:
• A glossary of terms,
• Transmission identification information,
• Electrical overview of the Transmission Control Module (TCM),
• Some notes that address safe workshop practices,
• Service notes relating to fasteners and consumable items used at various stages throughout this section,
• Special tools required to work on the transmission,
• Fastener torque specifications, and
• Transmission specifications.
For all information relating to the mechanical construction and function of the 4L60E automatic transmission, refer to the
General Motors Powertrain Group Electronically Controlled Automatic Transmission Technician’s Guide.
This guide includes such information as:
• Transmission Cutaway Views,
• Principles of Operation,
• Power Flow,
• Complete Hydraulic Circuits,
• Bushing and Bearing Locations,
• Seal Locations and
• Illustrated Parts List.
NOTE
Specifications quoted in this General Motors
Powertrain Group Electronically Controlled
Automatic Transmission Technician Guide may
not be for the vehicle you are working on. For
correct specifications refer to
7 Transmission Specifications.
Recommendations
When servicing the transmission, all parts should be cleaned and inspected. Individual units should be reassembled
before disassembly of other units to avoid confusion and interchanging of parts.
a Thoroughly clean the transmission exterior before removal of any component.
b Disassembly and reassembly must be made on a clean work bench. Cleanliness is of the utmost importance, the bench tools and parts must be kept clean at all times.
c Before installing screws and other fasteners into aluminium parts, dip screw threads into transmission fluid to prevent galling aluminium threads and to prevent screws from seizing.
d To prevent thread stripping, always use a torque wrench when installing screws or nuts.
e If threads in aluminium parts are stripped or damaged, the parts can be made serviceable by the use of commercially available thread inserts.
f Protective tools must be used when assembling seals to prevent damage. The slightest flaw in the sealing surface of the seal can cause an oil leak.
g Aluminium castings and valve parts are very susceptible to nicks, burrs, etc. and should be handled with care.
h Expand Internal snap rings and compress external snap rings if they are to be re-used to ensure proper seating when reinstalled.
i Do not re-use removed O-rings, gaskets and oil seals.
j Teflon oil seal rings should not be removed unless damaged.
k During assembly of each unit, all internal moving parts must be lubricated with transmission fluid.
Oil Cooler Pipes
Should any transmission fluid cooling pipe suffer accidental damage, a genuine replacement pipe must be fitted. Refer to
the current release of PartFinder™ to determine the correct part number for the particular engine and pipe involved.
Reworking of damaged pipes or hand made replacements are not permitted.

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ISUZU KB P190 2007

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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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 7C1–10
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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