2007 ISUZU KB P190 torque

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-91

• Feedback current value is less than 92 mA
(2)
All of the following conditions are met for 0.5
seconds or more continuously. (DTC P0963)
• 1 second or more passed after open failure
detection condition is met or open failure is not
detected after ignition “ON”.
• Feedback current value is more than 1357 mA.
Action Taken When The DTC Sets
• No squat control.
• No line pressure reduction control at gear change.
• No lock-up control.
• No slope control.
• No torque reduction control.
• No line pressure reduction control at garage.
• Line pressure FULL output.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• No pressure control solenoid Feedback stuck failure detection.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
•
The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
Circuit/System Testing DTC P0962 or P0963

Step Action Value(s) YES NO
1
W as the On-Board Diagnostic (OBD) System Check
performed? — Go to
Step 2 Go to OBD
System Check
2 1. Install a scan tool.
2. Turn “ON” the ignition.
3. Record scan tool data.
4. Operate the vehicle within scan tool data.

Does a scan tool indicate DTC P0962 or P0963? — Go to
Step 3 Refer to
Diagnostic Aids
3 Measure the resistance of pressure control solenoid.
1. Turn “OFF” the ignition.
2. Disconnect the automatic transmission connector.
3. Measure the resistance between automatic
transmission terminal E54-2 and automatic
transmission terminal E54-6.

Is the resistance specified value? 5 to 5.6Ω at
20 °C (68 °F) Go to
Step 4 Go to Step 7

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ISUZU KB P190 2007

7A2-94 TRANSMISSION CONTROL SYSTEM (AW30–40LE)


Condition For Setting The DTC
The TCM detects following conditions for 0.5 seconds
continuously at shifting.
• Voltage at connector pin is 0V when solenoid is “ON”.
(DTC P0973)
• Voltage at connector pin is ignition voltage when
solenoid is “OFF”. (DTC P0974)
Action Taken When The DTC Sets
• No L-up control.
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control.
• No line pressure reduction control at garage.
• No input revolution sensor failure detection.
• No shift solenoid failure detection.
• No L-up solenoid failure detection.
• Change to emergency mode.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
•
The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.

Circuit/System Testing DTC P0973 or P0974

Step Action Value(s) YES NO
1
W as the On-Board Diagnostic (OBD) System Check
performed? — Go to
Step 2 Go to OBD
System Check
2 1. Install a scan tool.
2. Start the engine.
3. Depress the brake pedal and place the select lever in D position.
4. Press the 3rd start switch. (Turn the 3rd start switch “ON”.)
5. Press the 3rd start switch again. (Turn the 3rd start switch “OFF”.)

Does a scan tool indicate DTC P0973 or P0974? — Go to
Step 3 Refer to
Diagnostic Aids
3 1. Turn “ON” the ignition with the engine “ON”.
2. Place the selector lever in the “P” position.
3. Measure the voltage between terminal C94-16 and terminal C94-1 (GND) on the TCM pigtail
connector by 5-8840-0285-0 DMM.

Is the voltage specified value? 8∼16V Go to
Step 4 Go to Step 10

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ISUZU KB P190 2007

7A2-98 TRANSMISSION CONTROL SYSTEM (AW30–40LE)

Condition For Setting The DTC
The TCM detects following conditions for 0.5 seconds
continuously at shifting.
• Voltage at connector pin is 0V when solenoid is “ON”.
(DTC P0976)
• Voltage at connector pin is ignition voltage when
solenoid is “OFF”. (DTC P0977)
Action Taken When The DTC Sets
• No L-up control.
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control (keep mode).
• No line pressure reduction control at garage.
• No input revolution sensor failure detection.
• No shift solenoid failure detection.
• No L-up solenoid failure detection.
• Change to emergency mode.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
•
The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.

Circuit/System Testing DTC P0976 or P0977

Step Action Value(s) YES NO
1
W as the On-Board Diagnostic (OBD) System Check
performed? — Go to
Step 2 Go to OBD
System Check
2 1. Install a scan tool.
2. Start the engine.
3. Depress the brake pedal and place the select lever in D position.
4. Press the 3rd start switch. (Turn the 3rd start switch “ON”.)
5. Press the 3rd start switch again. (Turn the 3rd start switch “OFF”.)

Does a scan tool indicate DTC P0976 or P0977? — Go to
Step 3 Refer to
Diagnostic Aids
3 1. Turn “ON” the ignition with the engine “ON”.
2. Place the selector lever in the “P” position.
3. Measure the voltage between terminal C94-15 and terminal C94-1 on the TCM pigtail connector by 5-
8840-0285-0 DMM.

Is the voltage specified value? 8∼16V Go to
Step 4 Go to Step 5

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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-105

DTC P2769 or P2770 (Flash Code 33)




RTW 77ALF001501

Circuit Description
The lock-up solenoid SL of the torque converter clutch
(TCC) controls the lock-up clutch by a signal according
to the lock-up position judgment of the TCM when the
vehicle runs.
This function can improve the fuel consumption to
almost the same extent as the manual transmission.
The lock-up solenoid SL is put into B+ by the TCM, so
that the solenoid is actuated with the result of lock-up.

Condition For Running The DTC
All of the following conditions are met.
(1) All of the following conditions are met for 2 seconds or more continuously.
• The supply voltage is more than 10.2 volts and
less than 15.5 volts.
(2) Not emergency mode.
(3) 0.025 seconds or more passed after the state o
f
energized solenoid is changed.


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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-113

(2) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication is receiving
enable.
• DTC Clear is not operating.

The following condition at ignition “OFF” form “ON” is
detected seven times in total in 1 cycle.
• Receiving BUS “OFF” information from CAN
controller.
Action Taken When The DTC Set
• Throttle judgment on torque reduction control, line
pressure control at stationary status, line pressure
reduction control at gear change and line pressure
reduction control at garage. (Throttle opening 100%)
• Line pressure FULL output.
• Throttle judgment on gear change control. (Throttle
opening 0%)
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control.
• No L-up control.
• Control Engine rpm at 7000rpm. (No inertia
calculation)
• Control actual torque at MAX.
• Control driver torque at MAX.
• Control engine coolant temperature at 80 °C (176 °F).
• No coast control.
• No 3rd Start mode control.
• No line pressure reduction control at garage.
• No output revolution sensor failure detection.
• No input revolution sensor failure detection.
• No selector position switch failure detection.
• No oil temperature sensor failure detection.
• No T/F Hi-Low SW failure detection.
• No speed mater signal failure detection.
• No throttle signal failure detection.
• No Engine torque signal failure detection.
• No engine coolant temperature signal failure
detection.
• No Engine revolution signal failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• No DTC U2105 failure detection.
• Cancel engine rpm condition of prerequisite of suppl
y
voltage failure detection.
• Control vehicle speed of speed meter at 0km/h.
• No torque reduction at stall.
• No cruise control.
• No warm up control.
• DTC stored.
• Check Trans “ON”.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
• The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
• Inspect the wiring for EMI (Electro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check fo
r
improperly installed electrical options. W hen this test
is performed, turn “OFF” on electronic auto parts
switches to improperly for a noise preventing.


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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-117

(3) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication is receiving
enable.
• DTC Clear is not operating.
(4) DTC U2104 is not detecting failure or not deciding failure.
Condition For Setting The DTC
Detection standard is met for 2.5 second continuously.
Detection standard:
If one or more ID sent from Engine Control Module
(ECM) is not completed receiving for 2 basic cycles
since last receiving completion.
Action Taken When The DTC Sets
• Throttle judgment on torque reduction control, line
pressure control at stationary status, line pressure
reduction control at gear change and line pressure
reduction control at garage. (Throttle opening 100%)
• Line pressure FULL output.
• Throttle judgment on gear change control (Throttle
opening 0%).
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control (keep mode).
• No L-up control.
• Control Engine rpm at 7000rpm (No inertia
calculation).
• Control actual torque at MAX.
• Control driver torque at MAX.
• Control engine coolant temperature at 80 °C (176 °F).
• No coast control.
• No 3rd Start mode control.
• No line pressure reduction control at garage.
• No output revolution sensor failure detection.
• No C-0 rev sensor failure detection.
• No selector position switch failure detection.
• No oil temperature sensor failure detection.
• No T/F Hi-Low SW failure detection (Execute T/F
judgment using only T/F-SW ).
• No speed mater signal failure detection.
• No throttle signal failure detection.
• No Engine torque signal failure detection.
• No engine coolant temperature signal failure
detection.
• No Engine revolution signal failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• Cancel engine rpm condition of prerequisite of suppl
y
voltage failure detection.
• Control vehicle speed of speed meter at 0km/h.
• No torque reduction at stall.
• No cruise control.
• No warm up control.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
• The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
• After more than 1 second has elapsed after the ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
• Inspect the wiring for EMI (Electro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check fo
r
improperly installed electrical options. W hen this test
is performed, turn “OFF” on electronic auto parts
switches to improperly for a noise preventing.


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TO MODEL INDEX
ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (AW30–40LE)
TABLE OF CONTENTS

Service Precaution .................................................. 7A3-2
Diagnosis ................................................................. 7A3-3
Basic Troubleshooting ........................................ 7A3-3
Manual Shifting Test ........................................... 7A3-9
Stall Test ............................................................... 7A3-9
Time Lag Test ...................................................... 7A3-10
Hydraulic Test ...................................................... 7A3-11
Road Test ............................................................. 7A3-12
Shift Point Chart and Lock-Up Point Chart ..........7A3-16
Shift Point Chart ................................................... 7A3-16
Lock-Up Point Chart ............................................ 7A3-17
Transmission Fluid Level and Condition ..............7A3-18
Inspection ............................................................. 7A3-18
ATF Replacement ................................................... 7A3-19
Inspection ............................................................. 7A3-19
Neutral Start Switch (Mode Switch) ......................7A3-20
Inspection ............................................................. 7A3-20
Removal ................................................................ 7A3-20
Installation ............................................................. 7A3-20
Brake Signal ............................................................ 7A3-21
Inspection ............................................................. 7A3-21
Input and Output Revolution Sensor ....................7A3-22
Inspection ............................................................. 7A3-22
Power and 3rd Start switch ....................................7A3-22
Inspection ............................................................. 7A3-22
Solenoid .................................................................... 7A3-23
Inspection ............................................................. 7A3-23
ATF Temperature Sensor ......................................7A3-24
Inspection ............................................................. 7A3-24

Select Lever ....................................................... 7A3-25 Remove or Disconnect .......................................7A3-26
Install or Connect ................................................ 7A3-26
Shift Cable .......................................................... 7A3-28 Remove or Disconnect .......................................7A3-28
Install or Connect ................................................ 7A3-29
Torque Specifications ......................................... 7A3-30
Transmission Control Module (TCM) ...................7A3-31
Removal ............................................................... 7A3-31
Installation ............................................................ 7A3-31
Shift Solenoid and Lock-Up Solenoid ..................7A3-32
Removal ............................................................... 7A3-32
Installation ............................................................ 7A3-33
Valve Body Assembly and Pressure Control Solenoid ................................................. 7A3-34
Removal ............................................................... 7A3-34
Installation ............................................................ 7A3-36
Rear Oil Seal (Adapter Housing, 4 ×4) ................. 7A3-37
Removal ............................................................... 7A3-37
Installation ............................................................ 7A3-37
Rear Oil Seal (Extension Housing, 4 ×2) .............. 7A3-38
Removal ............................................................... 7A3-38
Installation ............................................................ 7A3-38
Transmission Assembly .........................................7A3-39
Transmission and Associated Parts .................7A3-39
Removal ............................................................... 7A3-40
Installation ............................................................ 7A3-44
Major Components .............................................. 7A3-49





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ISUZU KB P190 2007

7A3-2 ON-VEHICLE SERVICE (AW30–40LE)
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require
a replacement after removal. ISUZU/GM will also
call out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.


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ISUZU KB P190 2007