engine ISUZU KB P190 2007 Workshop Repair Manual

TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-167
Second Gear
Legend1. Input shaft
2. Front planetary carrier
3. Front pinion gear
4. Front sun gear
5. Rear sun gear
6. Rear pinion gear
7. Rear internal gear
8. Output shaft
9. Reverse clutch 10. 2-4 brake
11. High clutch
12. Front internal gear
13. Rear planetary carrier
14. Low clutch
15. Low & reverse brake
16. Low one-way clutch
17. Parking pawl
The driving force from the input shaft (1) is transmitted
to the rear sun gear (5) and reverse & high clutch drum.
As in the case of the 1st gear, the low clutch (14) is
engaged and the movement of the rear internal gear (7)
is restricted. Since the 2-4 brake is engaged (10), the
front sun gear (4) is fixed. As a result, movement of the
rear internal gear (7) is restricted, and the driving force
transmitted to the rear sun gear (5) rotates the rear
planetary carrier (13) clockwise. The rotating speed of
the rear planetary carrier (13) is higher than in 1st gear as the rear internal gear (7) rotates. When decelerating,
the engine brake is applied.

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7A2-168 TRANSMISSION CONTROL SYSTEM (JR405E)
Third Gear
Legend1. Input shaft
2. Front planetary carrier
3. Front pinion gear
4. Front sun gear
5. Rear sun gear
6. Rear pinion gear
7. Rear internal gear
8. Output shaft
9. Reverse clutch 10. 2-4 brake
11 . H i g h c l u t c h
12. Front internal gear
13. Rear planetary carrier
14. Low clutch
15. Low & reverse brake
16. Low one-way clutch
17. Parking pawl
The driving force from the input shaft (1) is transmitted
to the rear sun gear (5) and reverse & high clutch drum.
As in the case of the 1st gear and 2nd gear, the low
clutch (14) is engaged and the movement of the rear
internal gear (7) is restricted. Since the high clutch (11)
is engaged, the driving force from the input shaft (1) is
directly transmitted to the rear internal gear (7). As a
result, the speed of the rear sun gear (5) and the rear
internal gear (7) becomes the same as that of the input
shaft (1), so that the rear pinion gear rotates (6) not independently but together with the rear sun gear (5)
and rear internal gear (7). When decelerating, the
engine brake is applied.

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ISUZU KB P190 2007

7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.
For shift interlock function, if the ignition key is out of
“LOCK” position, the shift lever select button can not be
pushed. (shift lever can not be operated.)

RTW 77ASH000901

AUTOMATIC TRANSMISSION FLUID (ATF)
Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Check the color and smell of the ATF.
If the ATF is abnormal color or smells burnt, replace it
and investigate the cause of trouble.
Coloor of ATF Condition Clear red Normality
Blackish discoloration Defects of power train
parts (clutches)
W hite turbidity Include water
Discoloration of red brown Deterioration of ATF

ATF LEVEL
Inspect
Hot Level
1. W arm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80 °C (176 °F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
positions.
Stop in each gear position just long enough for the transmission to engage.
5. Return the select lever to either “P” or “N”.
6. Remove the ATF level dipstick.
7. W ipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.
9. Remove the dipstick.
The ATF level should be inside the “H” range on the dipstick.
242R300001
If the ATF level is below the “H” range, ATF must be added.

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ON-VEHICLE SERVICE (JR405E) 7A3-3
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20 °C (68 °F) before the
cold level check is made.
1. Park the vehicle on a level surface.
2. Apply the parking brake firmly.
3. Start the engine and allow it to warm up.
The engine coolant temperature gauge needle should be midway between the “C” mark and “H”
mark.
4. Let the engine run at idle.
Move the select lever slowly through all the gea
r
ranges.
Stop in each range just long enough for the transmission to engage.
5. Return the select lever either “P” or “N”.
6. Remove the ATF level dipstick.
7. W ipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.

9. Remove the dipstick.
The ATF level should be inside the “C” range on the dipstick.
If the ATF level is below the “C” range, ATF must be added.
242R300002


ATF CHANGE
1. Park the vehicle on level ground and block the rear
wheels.
2. Start the engine and allow it to idle until the ATF reaches a temperature of 40-50 °C (104-122 °F).
3. Stop the engine.
4. Raise the front to the vehicle and support with suitable safety stands.
5. Remove the drain plug from the oil pan and drain the ATF (approximately 6 liters).





6. Remove the oil pan.
7. Inspect the oil pan (details written below).
8. Install the oil pan.
Note:
Use a new gasket. Clean the oil pan and magnet.
Oil pan bolt torque : 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
9. Replace the gasket and install the drain plug.
Drain plug torque : 35 N ⋅m (3.6 kgf ⋅m/26 lb ⋅ft)
Note:
Do not reuse the old washer (gasket).
Clean the drain plug (especially the threaded section).
10.Remove the safety stands and wheel blocks.
11.Pour about 5 liters of new ATF.
12. Start the engine. W ith your foot on the brake, move the shift lever through each gear range, and shift to
“P” range.
13.Check the ATF level. Add more ATF carefully as necessary using the dipstick. Refer to “ATF LEVEL”
preciously in this section.
Note:
Keep the engine idle (do not stop it) during the ATF level
adjustment.


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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.

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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.




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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.

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MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.


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MSG MODEL 7B-9
Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.




Starter Motor
Remove the starter motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the No.3
crossmember
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.


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MSG MODEL 7B-11
Important Operations - Installation
Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
installation procedure.



Transmission
1. Apply a thin coat of molybdenum disulfide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into position behind the engine.




4. Slowly operate the transmission jack to raise the
transmission until the rear of the transmission is at the
same level as the No.3 crossmember
1 .
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3 crossmember and the floor panel
2 .



6. Slowly raise the transmission jack until the front of the
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be the same.
7. Install the gear control box the transmission.
8. Align the top gear shaft spline with the clutch drive plate spline.
9. Install the transmission to the engine.
Tighten the transmission nuts and bolts as shown in the figure.




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ISUZU KB P190 2007