sensor ISUZU KB P190 2007 Workshop Repair Manual

ON-VEHICLE SERVICE (AW30–40LE) 7A3-47



RTW 77ASH002201




RTW 77ASH002301

19.Install the transfer assembly.(4 ×4 only)
•
Apply a thin coat of molybdenum disulfide
grease to the input shaft spline.
Torque: 41 N ⋅
⋅⋅
⋅
m(4.2 kgf ⋅m/30 lb ⋅ft)





RTW 77ASH001701
20.Connect two harness clips (1) of the tansfer upper
side.



1
1


RTW 77ASH001601
21.Connect the speed sensor connector.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A3-48 ON-VEHICLE SERVICE (AW30–40LE)
22.Connect the 2W D-4W D switch connector (1),
neutral switch connector (2), actuator connecto
r
(3) and speed sensor connector (4).





RTW 77ASH001801



RTW 77ASH001901






RTW 77ASH002001
23.Install the rear propeller shaft.
NOTE: Align alignment marks on the flange.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅m/43 lb ⋅ft)






RTW 77BSH000201
24.Install the center bearing on the crossmember.
Torque: 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅m/51 lb ⋅ft)
25.Install the front propeller shaft.(4 ×4 only)
NOTE: Align alignment marks on the flange.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅m/43 lb ⋅ft)
26.Remove the drain plug from oil pan and drain the fluid.
27.Install the drain plug. Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅m/14 lb ⋅ft)
28.Pour the transmission oil.
29.Remove suitable stands.
30.Connect battery ground cable.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4–2 UNIT REPAIR (AW30–40LE)
Major Components (1)
Major Components (1) and Associated parts
RTW77AMF003801
EndOFCallout
Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
Legend (1) Torque converter
(2) Neutral start switch
(3) Elbow
(4) Oil temperature sensor
(5) Breather hose (6) Output revolution sensor
(7) Adapter housing
(8) Transmission assembly
(9) Select lever
(10) Input revolution sensor

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–3
3. Remove the neutral start switch (Mode switch). Unstake the lock washer.
 Remove the nut and bolt, and then remove the
neutral start switch.
 Remove the lock washer.
RTW77ASH003401
4. Remove the two elbows from transmission case.
240RY00001
5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4 ×4).
9. Remove the output revolution sensor (4 ×2).
10. Remove the speedometer sensor, speedometer driven gear and plate (4 ×2).
11. Remove the extension housing (4 ×2).
12. Remove the adapter housing (4 ×4). 13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (1)
Holding fixture base: 5-8840-0003-0 (2)
RTW77ASH003301

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4–4 UNIT REPAIR (AW30–40LE)
Components (1)
Reassembly
1. Install a new gasket and the extension housing(4×2) to the transmission case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
2. Install the speedometer driven gear, plate, and speedometer sensor (4 ×2).
Torque:
Plate bolt – 15 N·m (1.5 kgf·m/11 Ib ·ft)
Speedometer sensor – 25 N·m (2.5 kgf·m/18 Ib ·ft)
3. Install the adapter housing (4 ×4).
 Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
241RY00020
 Apply liquid gasket (TB1281 –B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
 Install the adapter housing to the transmission
case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
4. Install the neutral start switch.  Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
 Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
 Install the lock washer and nut.
Torque: 7 N·m (0.7 kgf·m/61 Ib ·in) 
Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (1.3 kgf·m/113 Ib ·in)
 Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW17ASH013601
5. Install the oil temperature sensor to the transmission case.
Torque: 15 N·m (1.5 kgf·m/11 Ib ·ft)
RTW77ASH003501

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–5
6. Install the elbow. Coat new O-rings with ATF, install them to the two
elbows.
 Install the two elbows as shown in the figure.
Torque: 29 N ·m (3.0 kgf ·m/22 Ib ·ft)
RTW77ASH003601
7. Install the select lever.
8. Install the output revolution sensor (4 ×2).
9. Install the output revolution sensor (4 ×4).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter. Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5 mm (0.53 in)
240RY00005

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–9
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C –2).
 Remove accumulator pistons and springs from
transmission case.
240RY00010
10. Applying compressed air to the oil hole, remove the B–0 accumulator piston and spring.
240RY00011
11. Remove the C –0 accumulator piston.
240RY00012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
 Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4 ×4).
 Remove the snap ring from the output shaft.
 Remove the rotor and key.
247R200002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4 ×2).
 Remove the snap ring from the output shaft.
 Remove the speedometer sensor drive gear, and
ball.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7A4–10 UNIT REPAIR (AW30–40LE)
16. Remove the spacer, rotor, key and snap ring (4×2).
 Remove the spacer, rotor and key.
 Remove the snap ring from the output shaft.
247L100001
Reassembly
1. Install the converter housing.
Torque:
M10 – 34 N ·m (3.5 kgf ·m/25 lb ·ft)
M12 – 57 N ·m (5.8 kgf ·m/42 lb ·ft)
240R200022
2. Install the snap ring, key and rotor (4 ×2).
 Install the snap ring to the output shaft.
 Install the key and rotor. 3. Install the spacer, ball, speedometer sensor drive
gear and snap ring (4 ×2).
 Install the spacer, ball and speedometer sensor
drive gear.
 Install the snap ring to the output shaft.
247L100001
4. Install the key, rotor and snap ring (4 ×4).
 Install the key and rotor.
 Install the snap ring to the output shaft.
247R200002

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CONSTRUCTION AND FUNCTION 7A1-1

SECTION 7A1
CONSTRUCTION AND FUNCTION (JR405E)
TABLE OF CONTENTS
PAGE
Description ................................................................................................................... ...7A1- 3
Construction ...............................................................................................................7A1 - 3
Main Data and Specification .....................................................................................7A1- 4
Number Plate Location ..............................................................................................7A1- 5
Electronic Control Components Location ...............................................................7A1- 6
Transmission Control Module (TCM) Peripheral Circuit .........................................7A1- 7
Structure and Function of Component .........................................................................7A1- 8
Torque Converter (with Lock-up Function) .............................................................7A1- 8
Oil Pump .....................................................................................................................7 A1- 9
Input Shaft ..................................................................................................................7 A1- 10
Output Shaft ...............................................................................................................7A1 - 10
Gear Shifting Mechanism ..........................................................................................7A1- 10
Control Valve ..............................................................................................................7A1 - 14
Oil Passage .................................................................................................................7A 1- 19
Parking Function ........................................................................................................7A1- 2 0
Inhibitor Switch ..........................................................................................................7A1- 21
Turbine Sensor ...........................................................................................................7A1- 22
Speed Sensor .............................................................................................................7A1- 22
Accelerator Pedal Position Sensor ..........................................................................7A1- 23
Engine Speed Sensor (=CKP Sensor) ......................................................................7A1- 23
Brake Switch ..............................................................................................................7A1- 24
Mode Select Switch ...................................................................................................7A1- 24
Transmission Control Module (TCM) .......................................................................7A1- 25
Control Mechanism ........................................................................................................7A1- 26
Content of Function and Control ..............................................................................7A1- 26
Control Item, Input and Output .................................................................................7A1- 29
Line Pressure Control ................................................................................................7A1- 30
Lock-up Control .........................................................................................................7A1- 3 0
Direct Electric Shift Control (DESC) .........................................................................7A1- 31

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CONSTRUCTION AND FUNCTION 7A1-3

DESCRIPTION
CONSTRUCTION



































1 Converter Housing 6 Low Clutch 11 Oil Pump
2 Torque Converter 7 Low & Reverse Brake 12 Control Valve
3 High Clutch 8 Output Shaft 13 Low One-way Clutch
4 Reverse Clutch 9 Extension Housing 14 Parking Gear
5 2-4 Brake 10 Input Shaft

Figure 1. Construction of Automatic Transmission

The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module
(TCM). There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift
Control: DESC) using duty cycle type solenoids, which ensure high shift quality.
This transmission also has a learning function and constantly checks the time of each clutch and brake
required for the shift in order to match this time with the target value for the optimum shift.

The TCM will automatically select the most appropriate shift points and lock-up points depending on the
Accelerator pedal opening, the vehicle speed and the vehicle load.
If any trouble arises in the speed sensor, APP sensor, solenoid, etc., the fail-safe control function is activated
to keep the running performance.
Problems with the sensors or the solenoids can quickly be detected with the self diagnosis procedure
described in this manual.

The JR405E automatic transmission consists of the torque converter, oil pump, input shaft, out put shaft,
planetary gears and control valves.
The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two
multiple plate brakes and a one-way clutch.
2WD
4WD

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007