start ISUZU KB P190 2007 Workshop Repair Manual

7B1-12 Manual Transmission (MUX)
22. Remove the transmission retaining nuts and bolts.Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.
23. Remove the transmission-transfer fixing bolts and nut, and disassemble the transfer from the
transmission. (4x4 model)
Installation
1. Apply grease (BESCO L-2 or equivalent) on the splined portion of the output shaft.
2. Connect the transfer to the transmission. (4x4 model)
3. Install the transmission-transfer fixing bolts and nut, and tighten them to the specified torque. (4x4
model)
Torque: 41 N ⋅m (4.2 kgf ⋅m/30 lb ⋅ft)
4. Apply a thin coat of molybdenum disulfide grease on the splined portion of the input shaft spline.
5. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the
engine.
6. Align the input shaft spline with the clutch driven plate spline.
7. Install the transmission assembly (4x2 model) or the transmission & transfer assembly (4x4 model)
to the engine.
• Tighten the transmission bolts to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
8. Apply a force 69 N ⋅m (7 kgf ⋅m/51 lb ⋅ft) to the tip of
the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.
Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N ⋅m (2.6 kgf ⋅m/19 lb ⋅ft). If
the shift fork will not move, then they are securely
engaged. 9. Connect harness clips on the transmission left
side.
10. Install the starter assembly.
• Tighten the starter bolts to the specified torque.
Torque: 94 N ⋅m (9.6 kgf ⋅m/69 lb ⋅ft)
11. Install the transmission rear mount to the transmission.
• Tighten the transmission rear mount bolts to the specified torque.
Torque: 50 N ⋅m (5.1 kgf ⋅m/37 lb ⋅ft)
12. Install the transmission crossmember by removing four bolts and nuts.
• Tighten the transmission crossmember bolts to the specified torque.
Torque: 67 N ⋅m (6.8 kgf ⋅m/49 lb ⋅ft)
13. Install the transmission rear mount nuts fixing on crossmember from transmission crossmember.
• Tighten the transmission rear mount nuts to the specified torque.
Torque: 52 N ⋅m (5.3 kgf ⋅m/38 lb ⋅ft)
Remove the transmission jack from transmission
side.
14. Install the fuel pipe bracket bolt and connect fuel pipe clip.
• Tighten the fuel pipe bracket bolt to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
15. Install the slave cylinder fixing bolts. • Tighten the slave cylinder bolts to the specifiedtorque.
Torque: 43 N ⋅m (4.4 kgf ⋅m/32 lb ⋅ft)
RTW77BSH007201

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7D1-12 TRANSFER CONTROL SYSTEM
Functions of Switch and indicator Lamp
Transfer-related indicator lamp and switch function

Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H position
for 0.1
second 1,0,1,0 Open Open Open Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro and
retrial
During
operation (Axle
drive) Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
Axle
waiting Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
4L start
of
operation On Off Off Off 4L position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation On Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4H to 4L
through neutral
4L
waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation 1,1,0,1 Closed Open Closed -----
4H start of
operation On Off Off Off 4H position
for 0.1
second 1,1,0,1 Closed Open Closed Switch
operation sensor

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TRANSFER CONTROL SYSTEM 7D1-13
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
During
operation On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving
4H
waiting Off Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed
4L to 4H
while
waiting
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
2H start of
operation On Off Off Off 2H position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed Axle drive
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation 1,0,1,0 Open Open Closed Axle
waiting
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----


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7D1-14 TRANSFER CONTROL SYSTEM
2H to 4H retrial

Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H
position for 0.1
second 1,0,1,0 Open Open Open -----
Start of
operation Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro)
(Go to 4H if synchro
complete) Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial X 2
Abandoned
operation (2H) Blinking
(4HZ) Off Off Off No
operation 1,0,1,0 Open Open Open Return to
2H
2H
indication
after
10second
s
Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.

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7D1-16 TRANSFER CONTROL SYSTEM
Transfer-related indicator lamp and switch function
Skip operation
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
4L start of
operation Off Off Off Off 4L
position for 0.1
second 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1
0,1,0,1 Closed Open Open -----
During
operation
(N)
On Blinking
(2HZ) Off Off No
operation
0,0,1,1
0,1,0,1 Closed Open Closed -----
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Open Closed Switch
operation sensor
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Closed 4H to 4L
while
driving
During
operation (Axle
drive) Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open
-----
Axle
waiting Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
4L waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation1,1,0,1 Closed Open Closed -----

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TRANSFER CONTROL SYSTEM 7D1-17
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
lamp 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H start
of
operation On On Off Off 2H
position for 0.1
second 1,1,0,1 Closed Open Closed
Switch
operation sensor
During
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (Passing through N) On
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (4H
waiting) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation (Axle) Off while
waiting for start of H shift Blinking
(2HZ) while
waiting for start of H shift Off Off
No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) at
end of H shift Off at end
of H shift Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.


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TRANSFER CONTROL SYSTEM 7D1-19
Transfer-related indicator lamp and switch function
2H→Neutral →2H
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
Neutral
start of
operation Off Off Off Off Neutral
position for 10
seconds 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Off Off Blinking
(2HZ) Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Off Off
Blinking
(2HZ) Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,1,1 Closed Open Closed -----
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation
(N)
Off Off Blinking
(2HZ) Off No
operation
0,0,0,1
0,1,0,1 Closed Closed Closed
4H to 4L
through
neutral
During
operation (N) Off Off
Blinking
(2HZ) Off No
operation 0,1,0,0 Closed Closed Closed Switch
operation sensor
Neutral Off Off On Off No
operation0,1,0,0 Closed Closed Open -----
2H start of
operation Off Off On Off 2H
position for 10
seconds 0,1,0,0 Closed Open Closed
Switch
operation sensor
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving

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TRANSFER CONTROL SYSTEM 7D1-47
3. Shifting from 4H to 4L
3-1 When the 4L indicator flashes at 2Hz
W hen shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is
completed. The phases of the engaged splines may sometimes deviate preventing completion of shifting. By
correcting the deviation of phases, shifting is completed.

Step 3-1:
(In case of AT): Set the select bar of the transmission to the D position.
(In case of MT): Set the lever of the transmission to a position allowing running and engage the clutch gently.
At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is
completed.
3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)
This condition occurs when torsional torque has been generated between the transmission and road surface
and the transfer standby mechanism cannot absorb it completely.

Step 3-2:
Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at
this time.)
3-3 When the 4L indicator flashes at a frequency of 4Hz
Shifting from 4H to 4L is restricted.
W hen the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:
3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).
Restriction on operation (Except 4JA1-T)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM
position).
Requirement to restrict the speed: Vehicle should be in stop. Due to the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 – R), the time to wait
becomes longer.
W aiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues for
3 minutes. After that, the waiting time increases up to 3 minutes in 2 minute intervals.
W hen it is clear that the above condition has continued and reduction of waiting time is required, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommended
(MT) should be at the neutral.

These requirements for permission should all be met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

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TRANSFER CONTROL SYSTEM 7D1-49
Step 4-3: (Same procedure as the step 3-3)
Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or below).
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position (stepping on the clutch lever is recommended).
Push the 4H button.
If shifting is not complete (indicator flashes at 2Hz), go to step 4-1.

5. When shifting from 4H or 4L to neutral
(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If torsional
torque has accumulated between the transmission and road surface, separation may be difficult.
Step 5-1:
If the operation is not complete, execute step 7 for confirmation.
(In case of AT): Set the transmission select lever to the D position. After confirming that the gears are at the neutral position, return the lever to the N
position.
(In case of MT): Set the transmission lever to a vehicle running position and engage the clutch gently. After confirming that the gears are at the neutral position, return the lever to the
neutral position
5-2 When the neutral indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is
impossible (restriction on operation).
Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch is recommended).
Keep pushing the 2H and 4L button for 10 seconds.
Follow the start procedure for confirmation. (Confirmation of drive force is not transferred; same as in
step 5-1)
After the confirmation, set the transmission to the neutral position in the case of MT or to the neutral
position in the case of AT.

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TRANSFER CONTROL SYSTEM 7D1-61
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once.
Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3.
Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace this
chart from the beginning.
3 Shift to 2H.
Can be shifted to 2H and then to
4H? Go to step 4.
Refer to the paragraph about
shifting from 2H to 4H.
In particular, check if not at the
Check4W D condition, return to
this chart and trace it from the
beginning.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Shift back to 4H and go to step 5.
5
Start the engine and use the
vehicle.
Does the speedometer run at
this time? Go to step 6.
Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble detected? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7
Run the vehicle for several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met? Failed controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1 second
or maximum 3 minutes,
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)


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