2007 ISUZU KB P190 service

ON-VEHICLE SERVICE (JR405E) 7A3-15
Torque Specifications
∗
∗∗
∗
N ⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
in)
N ⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)




RTW 77ALF000401

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-16 ON-VEHICLE SERVICE (JR405E)
SOLENOIDS, OIL PRESSURE SWITCH AND OIL TEMPERATURE
SENSOR
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure switch connector (wire color: W hite)
4. Low and reverse brake duty solenoid connector
(wire color: Pink and W hite)
5. High clutch duty solenoid connector
(wire color: Green and Gray)

6. Lock-up duty solenoid connector
(wire color: Yellow and Black)
7. 2-4 brake duty solenoid connector
(wire color: Blue and Brown)
8. Low clutch duty solenoid connector
(wire color: Orange and Black)
9. Line pressure solenoid connector
(wire color: Pink)




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-17
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Drain the fluid.
Refer to “ATF CHANGE” in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign material, the oil strainer must be replaced.
Further inspection is required to determine the source of the foreign material.
6. Remove the harness assembly (including the oil temperature sensor).
7. Remove the 11 bolts and the solenoid fixing plate.
8. Remove the 6 solenoids and 3 oil pressure switches.

Inspect
Oil pressure switch
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the oil pressure switch to check the oil pressure switch
continuity between the connector and screw.
Replace the oil pressure switch if the result of inspection
is abnormal.

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between
harness terminals 7 and 6 (ground).
Oil temperature sensor resistance:
2,400~2,600 ohms (20 °
°°
°
C)
244L300011

Solenoid
Measure the resistance of each solenoid.
Resistance:
Brown connector – 3.0~3.4 ohms (20 °
°°
°
C)
Gray connector – 12.0~13.2 ohms (20 °
°°
°
C)
White connector – 12.2~13.4 ohms (20 °
°°
°
C)
Replace the solenoid if the result of inspection is
abnormal.

Install or connect
1. Install the O-rings to each of the solenoids.
2. Install the 6 solenoids and 3 oil pressure switches.
Line pressure solenoid bolt torque:
8 N·m (0.8 kgf·m/69 lb·in)
Oil pressure switch bolt torque:
4 N·m (0.4 kgf·m/35 lb·in)
3. Install the solenoid fixing plate together with the harness brackets.
Number Length (Color)
Solenoid fixing plate bolt
(A)
(B)
4
7
16 mm (0.63 in) (Gold)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
4. Install the harness assembly.
5. If removed, install the oil strainer.
Number Length (Color)
Oil strainer bolt
(C)
(D)
9
4
13 mm (0.51 in) (Silver)
45 mm (1.77 in) (Silver)

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
7. Fill the fluid.
Refer to “ATF CHANGE” in this section.
8. Connect the negative battery cable.
9. Remove the wheel blocks.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-18 ON-VEHICLE SERVICE (JR405E)
CONTROL VALVE ASSEMBLY
244L300001
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Drain the fluid.
Refer to “ATF CHANGE” in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign material, the oil strainer must be replaced.
Further inspection is required to determine the source of the foreign material.
6. Disconnect the 2 harness connectors leading to the control valve.
7. Remove the 12 bolts and the control valve assembly.
Number of bolts Length
10 (A)
2 (B) 40 mm (1.57 in)
30 mm (1.18 in)

Note:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the
valve from turning).


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12 fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Fill with the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. W hen an abnormal amount of debris is found.
2. W hen an abnormal wear or chips on gears and shafts is found while overhauling.
3. W hen there is abnormal clutch facing wear and oil contamination found.

Procedures
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with suitable safet
y
stands.
4. Disconnect the fluid cooler lines at the transmission case and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using solvent and compressed air.
Note:
DO NOT exceed (200 kPa/2.0 kgf/cm
2/28 psi) air
pressure, or damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (4.5 kgf·m/33 lb·ft)
8. Replenish the ATF.
9. Start the engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all the debris from the fluid cooler circuit.
Move the select lever through the various ranges and return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF must be added.
10. Connect the negative battery cable.
11. Remove the safety stands.
12. Remove the wheel blocks.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-20 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION ASSEMBLY

RUW 57ALF000201
Legend
1. Shift Cable
2. Propeller Shaft
3. Engine Harness
4. ATF Level Dipstick & Filler Tube
5. Under Cover
6. Bolt

7. ATF Pipe
8. Crossmember
9. Transmission Mount
10. Starter Motor
11. Bolt
12. Automatic Transmission

Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with the suitable safety stands.




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-21
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.
6. Loosen (do not remove) the nuts securing the exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the transmission.
8. Remove the fuel pipe bracket.
P1010013

P1010014
9. Remove the ATF level dipstick and tube.
10. Remove the undercover.
11. Rotate the ring gear and remove the 6 torque
converter bolts.
P1010016
12. Remove the automatic transmission fluid cooling pipe.
P1010060
13. Place a jack beneath the engine to support it.
14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the engine and transmission. Do not allow the radiato
r
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the engine.
18. Lower the transmission from beneath the vehicle. Take care not to damage the breathers.

Install or Connect
1. Install the transmission to the engine and tighten the bolts.
Bolt torque : M10 40 N·m (4.1 kgf·m/30 lb·ft)
M12 76 N·m (7.7 kgf·m/56 lb·ft)
2. Install the cable bracket to the transmission.
3. Connect the engine harness connectors.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-22 ON-VEHICLE SERVICE (JR405E)

4. Install the transmission mount.
Bolt torque (rubber to transmission) :
50N·m (5.1 kgf·m/37 lb·ft)
Nut torque (rubber to crossmember) :
52N·m (5.3 kgf·m/38 lb·ft)
5. Install the 3rd crossmember.
Bolt and Nut torque : 67 N·m (6.8 kgf·m/49 lb·ft)
Bolt torque : 50 N·m (5.1 kgf·m/37 lb·ft)
6. Install the automatic transmission fluid cooling pipe.
7. Install the torque converter bolts.
Bolt torque : 29 N·m (3.0 kgf·m/22 lb·ft)
8. Install the undercover.
Bolt torque : 9 N·m (0.9 kgf·m/78 lb·in)
9. Install the ATF level dipstick and tube.

10. Install the fuel hose bracket.
Bolt torque : 10 N·m (1.0 kgf·m/87 lb·in)
11. Tighten the nuts securing the exhaust manifold and the exhaust pipe.
Bolt torque : 43 N·m (4.4 kgf·m/32 lb·ft)
12. Install the rear propeller shaft assembly.
Flange bolt torque : 59 N·m (6.0 kgf·m/43 lb·ft)
Center bearing bracket bolt torque :
69 N·m (7.0 kgf·m/51 lb·ft)
13. Install the shift cable.
14. Connect the negative battery cable.
15. Remove the safety stands.
16. Remove the wheels blocks.

Torque Specifications
N ⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm



RTW 67ALF000301

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007