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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TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-169
Fourth 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.
Since the 2-4 brake (10) is engaged, the front sun gear
(4) is fixed. In addition to this the high clutch (11) is
engaged. As a result, the front pinion gear (6) rotates
itself together with other gears clockwise. This rotation
increases the speed of rotation of the front internal gear
(12) and is transmitted to the output shaft (8).

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7A2-170 TRANSMISSION CONTROL SYSTEM (JR405E)
Special Tools and Equipment
Special Tools and Equipment
Illustration Tool Number / Description
5-8840-2835-0 (J-35616-C)Connector Test Adapter Kit
(With Test Lamp)
5-8840-0285-0 (J-39200) Digital Multimeter
Te c h 2 K i t
5884028350

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ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)
TABLE OF CONTENTS
PAGE
Description ................................................................................................................... ... 7A3 – 2
Automatic Transmission Fluid (ATF) ............................................................................ 7A3 – 2
ATF Level ..................................................................................................................... .... 7A3 – 2
ATF Change .................................................................................................................... . 7A3 – 3
Transmission Control Module (TCM) ............................................................................ 7A3 – 5
Inhibitor Switch .............................................................................................................. . 7A3 – 6
Speed Sensor .................................................................................................................. 7A3 – 8
Turbine Sensor ............................................................................................................... 7A3 – 9
Power and 3rd Start Switch ........................................................................................... 7A3 – 9
Select Lever .................................................................................................................. ... 7A3 –10
Shift Cable ................................................................................................................... .... 7A3 –13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 –16
Control Valve Assembly ................................................................................................. 7A3 –1 8
Flushing the Transmission Fluid Cooler and Line ...................................................... 7A3 –19
Transmission Assembly ................................................................................................. 7A3 –20
Special Service Tool ....................................................................................................... 7A 3 –23



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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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7A3-4 ON-VEHICLE SERVICE (JR405E)



RTW 07ASH000101

Inspect
1. Check the drain plug tip for adhesion of foreign
substances.
2. Check the drained ATF for color, smell and inclusion of foreign substances.
3. Check the oil pan bottom and magnet for adhesion o
f
foreign substances.
If a problem is discovered during those checks, the Automatic transmission must be overhauled.
Note:
The torque converter and the oil strainer need replacing
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.
In addition, flush the ATF cooler circuit.





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ON-VEHICLE SERVICE (JR405E) 7A3-5
TRANSMISSION CONTROL MODULE (TCM)



RTW 37ALF001901

Remove and Disconnect
1. Disconnect the negative battery cable.
2. Remove the connectors.
3. Remove the fixing nuts and remove the TCM (1) from the bracket.
Note:
The TCM is fitted under the instrument panel of the
driver’s compartment via three stud bolts.


Install or Connect
Follow the removal steps in the reverse order. Be
absolutely sure that the connectors are securely
fastened.




RTW 77ASH000801



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7A3-6 ON-VEHICLE SERVICE (JR405E)
INHIBITOR SWITCH
The inhibitor switch is attached to the right side of the
transmission.

Inspect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Disconnect the harness connectors.
4. Use an ohmmeter to check the inhibitor switch continuity between the following terminals as shown
in the figure.
5. Place the select lever in the “N” position.
249R300001
6. Move the select lever to either side.
Check the inhibitor switch continuity between the terminals shown in Step 4.
The continuity readings should remain fairly stead
y
as the select lever is moved.
If there is no continuity or the continuity is intermittent, the inhibitor switch must be adjusted.

Adjust
1. Disconnect the shift cable from the lever.
2. Loosen the inhibitor switch bolts.
3. Use the inhibitor switch set plate to align the neutral holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inibitor switch is not correctly adjusted, the
automatic transmission will not function normally.



4. Tighten the 2 inhibitor switch bolts to the specified
touque.
Torque: 6 N·m (0.6 kgf·m/52 lb·in)
47INH-SW 01
5. Remove the inhibitor switch set plate.
6. Connect the shift cable to the lever.
7. Connect the harness connector.

Remove or Disconnect
1. Remove the cable bracket (1) from the transmission.
2. Disconnect the shift cable (2) from the lever (3).
3. Disconnect the harness connectors.
4. Remove the inhibitor switch bolts.
5. Remove the inhibitor switch (4) from the transmission.

238R300001



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