engine ISUZU KB P190 2007 Workshop Repair Manual

ON-VEHICLE SERVICE (AW30–40LE) 7A3-43
19.Remove the under cover (1).





RTW 77ASH002601
20.Remove the torque converter bolts by turning the
crank shaft.
21.Remove the four transmission bolts.
22.Disconnect the two fuel pipe clips (1) on the transmission crossmember left side.




RTW 77ASH002701
23.Support transmission assembly with a
transmission jack.





RTW 77BSH000401
24.Support engine assembly with a engine jack.
25.Remove the transmission crossmember. • Remove the transmission mount nuts.
• Remove the transmission crossmember bolts
and nuts.
26.Remove the transmission assembly from the vehicle.

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7A3-44 ON-VEHICLE SERVICE (AW30–40LE)
Installation
1. Attach the transmission assembly to the engine.
• Slowly raise transmission jack until front of the
transmission assembly is aligned with rear o
f
the engine.
•
Attach the transmission assembly to the
engine.
• Tighten engine transmission bolts as shown in
the figure.





RTW 77ALF000701
2. Install the transmission crossmember.
• Install the transmission crossmember bolts and
nuts.

• Install the transmission mount nuts.
Torque: Crossmember ∼
∼∼
∼
Frame
･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･
76 N ⋅
⋅⋅
⋅
m (7.8 kgf ⋅m/56 lb ⋅ft)
Crossmember ∼
∼∼
∼
Transmission mounting
･････････････
52 N⋅
⋅⋅
⋅
m (5.3 kgf ⋅m/38 lb ⋅ft)


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ON-VEHICLE SERVICE (AW30–40LE) 7A3-45
3. Remove a engine jack.
4. Remove a transmission jack.
5. Connect the two fuel pipe clips (1) on the transmission crossmember left side.




RTW 77ASH002701
6. Install the torque converter bolts.
Torque: 29 N ⋅
⋅⋅
⋅
m(3.0 kgf ⋅m/22 lb ⋅ft)
NOTE: Do not reuse the torque converter bolts.
7. Install the under cover(1). Torque: 8 N ⋅
⋅⋅
⋅
m(0.8 kgf ⋅m/69 lb ⋅in)





RTW 77ASH002601
8. Connect two ATF pipes.
Torque: 44 N ⋅
⋅⋅
⋅
m(4.5 kgf ⋅m/33 lb ⋅ft)
9. Install the ATF pipe bolt (1).




RTW 77ASH002501
10.Connect the starter assembly with shift cable
bracket.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)
11.Connect the shift cable bracket on the transmission side.
12.Install the fuel pipe bracket bolt (1) on clutch housing lower left side.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)





RTW 77ASH002401
13.Install the oil level gauge and upper guide tube.



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7A4–98 UNIT REPAIR (AW30–40LE)
Main Data and Specifications
General Specifications
Remaks
Model AW30–40LE
Engine 4JJ1-TC High Output (3.0L)
Type Electronic control planetary gear type
3–element 1 –stage 2 –phase type
(with lock-up mechanism)
Gear ratio 1st 2.804
2nd 1.532
3rd 1.000
4th (O/D) 0.705
Reverse 2.394
Oil used Name Exxon Mobil ATF-3309
Q'ty (l) 8.7
Torque conver ter 2300 ± 200 Stall speed (rpm)
Friction element Forward clutch C–16
Number of discs
Direct clutch C–25
OD direct clutch C–03
Second coast brake B–1 40 mm Band width or
Number of discs
Second brake B–25
Number of discs
First and reverse brake B–37
Overdrive brake B–05
Clutch One-way clutch No.1 F–12 2
Number of
sprage
One-way clutch No.2
F–22 8
OD one-way clutch F–02 4
Planetary gear Front planetary Sun gear 42
Number of teeth
Pinion gear
19
Ring gear 79
Rear planetary Sun gear 33
Pinion gear 23
Ring gear 79
O/D planetary Sun gear 33
Pinion gear 23
Ring gear 79

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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

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7A1-6 CONSTRUCTION AND FUNCTION
ELECTRONIC CONTROL COMPONENTS LOCATION
4WD Only 4W D Only
Instrument panel (Meter)







Speed meter (2WD Only)
Shift position indicator lamp
POWER DRIVE, 3rd START
indicator lamp
A/T OIL TEMP indicator lamp
CHECK TRANS indicator lam
p
Brake pedal





Brake Switch
Transmission Control Module (TCM)

Electrical source






Ignition
Battery voltage
Speed sensor
Turbine sensor
Inhibitor switch
ATF thermo sensor
High clutch oil pressure switch
2-4 brake oil pressure switch
Low & Reverse brake oil pressure
switch
Line pressure solenoid
Low clutch solenoid
High clutch solenoid
2-4 brake solenoid
Low & Reverse brake solenoid
Lock-up solenoid
Transmission
Transfer Control Module
Transfer




4L mode switch
Engine




Engine speed sensor
Accelerator pedal Position Sensor


Engine Control Module (ECM)
Data link connector
Select lever







Power Drive
, 3rd Start select switch

Figure 3. Electronic Control Components Location

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7A1-8 CONSTRUCTION AND FUNCTION
STRUCTURE AND FUNCTION OF COMPONENT
TORQUE CONVERTER (WITH LOCK-UP FUNCTION)
• The torque converter is a device for transmitting the engine torque to the transmission. It transmits power
by means of oil when the lock-up clutch is disengaged, and by means of a lock-up clutch when it is
engaged.
• The torque converter is of the symmetrical, three-element, single-stage, two-phase type.
• As shown in the drawing, the symmetrical three-elements refer to three elements (components) consisting
of impeller (1), turbine (2) and stator (3) that are arranged symmetrically (figure 5).
• "Single-stage" means that there is only one turbine as an output element; "two-phase" means that the
pump impeller acts as a torque converter when the turbine speed is comparatively low, and as a fluid
coupling when the speed is high.


















1. Pump Impeller
2. Turbine Runner
3. Stator














1. Pump Impeller
2. Turbine Runner
3. Stator
4. Converter Cover
5. One-way Clutch
6. Lock-up Piston
7. Torsion Damper

Figure 5. Torque Converter
Figure 6. Construction of Torque Converter

Lock-up mechanism
• "Lock-up" refers to a fixed state of the lock-up clutch inside the torque converter and thus connects the
engine directly to the transmission.
• The hydraulic pressure for the lock-up control is supplied from two circuits.

When the lock-up clutch is disengaged (Figure 7) • When the lock-up is disengaged, the torque converter operating pressure is supplied from the oil pass age
(A) to between the cover and the lock-up piston, and separates the lock-up piston clutch facing and
converter cover.
• As a result, the engine drive power is transmitted from the converter cover to the pump impeller, to the
ATF and to the turbine. The torque converter functions as a fluid connector in this condition.
• The torque converter operating pressure is supplied from oil passage (A), and passes through oil passage
(B).

When the lock-up clutch is engaged (Figure 8) • When the lock-up is engaged, the torque converter operating pressure is supplied from oil passage (B) to
the oil pump impeller, the turbine, and then to the stator side. The oil between the lock-up piston and
converter cover is drained.
• Since the force acting on the right side of the lock-up piston is greater than the force on the left side, it
connects the lock-up piston clutch facing with the converter cover, thereby increasing the transmission
efficiency.

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CONSTRUCTION AND FUNCTION 7A1-9


Figure 7. Lock-up Control (Disengaged) Figure 8. Lock-up Control (Engaged)
OIL PUMP
• The oil pump generating oil pressure is a small-size trochoid gear type oil pump. It feeds oil to the torque
converter, lubricates the power train mechanism, and feeds the oil pressure to the oil pressure control unit
under pressure.
• The oil pump is located behind the torque converter. Since the inner rotor in the oil pump is fitted with
the drive sleeve of the torque converter, it works using power from the engine.

Figure 9. Construction of Oil Pump Figure 10. Location of Oil Pump
• When the inner rotor in the oil pump rotates, ATF is sucked in from the oil pan, passed between the inner
rotor, outer rotor and crescent, and then discharged. This discharged pressure is sent to the pressure
regulator valve in the control valve, and adjusted as required for operating the A/T. The flow rate under
pressure increases or decreases in proportion to the number of rotations.


Figure 11. Operation of Oil Pump

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7A1-10 CONSTRUCTION AND FUNCTION
INPUT SHAFT
• The input shaft has some oil holes, through which lubricating ATF is supplied to the torque converter, the
bearings, etc.
• The input shaft is fitted to the turbine runner in the torque converter, the reverse & high clutch drum and
the rear sun gear by means of the spline. Therefore, the engine driving force received by the torque
converter is transmitted to the reverse & high clutch drum and rear sun gear.

OUTPUT SHAFT
• The output shaft has some oil holes, through which the lubricating ATF is supplied to the bearings, the
planetary gear unit, etc.
• The output shaft transmits the engine driving force from the planetary gear to the propeller shaft.
• The front internal gear is fitted with the rear carrier assembly by spline. The parking gear is also fitted by
spline. By fixing this gear mechanically, the output shaft is fixed as required when parking the vehicle.

GEAR SHIFTING MECHANISM
• The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate
brakes and a one-way clutch. They are activated in different combinations in any of four forward and one
reverse gear positions.

Principle of gear shifting (Figure 12) • Planetary gears have the advantage of a compact configuration because of the way they are constructed
with a single central shaft.
• Also, unlike the manual transmission gears that require changing of the gear mesh, the gear ratio of the
planetary gears can be changed more easily by locking, releasing or rotating only some of their parts.
• A planetary gear is made up of a sun gear (1) at its center, and pinion gears (2) each of which rotates
about its own center and around the sun gear, as shown. They are all contained within the internal gear
(3).
• Also, since the pinion gears are further supported by the planetary carrier (4), they rotate as a unit in the
same direction, and at the same rate.
• As shown below, each planetary gear is constructed of three elements; a sun gear, pinion gears, an
internal gear and a planetary carrier. Gear shifting is achieved by conditioning two of the three elements,
namely the sun gear, the internal gear and planetary carrier.
• The planetary gears are locked by the clutch, brake and one-way clutch according to the gear shifting.
















1. Sun Gear
2. Pinion Gear
3. Internal Gear
4. Planetary Carrier

Figure 12. Planetary Gear

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CONSTRUCTION AND FUNCTION 7A1-21
INHIBITOR SWITCH
• The inhibitor switch is installed on the right side of the transmission main unit to detect the select lever
position.
• The inhibitor switch is connected with the starter SW circuit. The engine cannot be started when the
select lever is at any position other than the P and N position.
• By moving the select lever, the combination of the inhibitor switch pins is changed. The current position of
TCM is detected based on the combination of the pins.
10 7 3 2 4 8 5 1 9 6
P
R
N
D
3
2
L





6345
10987
21



Terminal Assembly Inhibitor Switch

Figure 36. Pin Assignment Figure 37. Location of Inhibitor Switch


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