ISUZU KB P190 2007 Workshop Repair Manual

7A4-14 UNIT REPAIR (JR405E)
Number Length (Color)
Control valve rocket
bolts and nuts (A) 2 (Plus 2 nuts) 50 mm (1.97 in) (Gold)
Upper body and
lower body fixing
bolts
(B) 2 45 mm (1.77 in) (Silver)
(C) 13 35 mm (1.38 in) (Silver)
Line pressure
solenoid fixing bolt
(D) 1 16 mm (0.63 in) (Gold)











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UNIT REPAIR (JR405E) 7A4-15
244L300003
Legend
1. High clutch oil pressure switch connector (wire color: Gray)
2. 2-4 brake oil pressure switch connector (wire color: Brown)
3. Low and reverse brake oil pressure switch connector (wire color: W hite)
4. Low and reverse brake duty solenoid connector (wire color: Pink and W hite)
5. High clutch duty solenoid connector (wire color: Green and Gray)


6. Lock-up duty solenoid connector (wire
color: Yellow and Black)
7. 2-4 brake duty solenoid connector (wire color: Blue and Brown)
8. Low clutch duty solenoid connector (wire color: Orange and Black)
9. Line pressure solenoid connector (wire color: Pink)







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7A4-16 UNIT REPAIR (JR405E)

12CV19

4. Solenoid
5. Oil pressure switch • Install the O-rings to each of the solenoids.
• Install the 6 solenoids together and the 3 oil pressure
switches.
NOTE:
Be sure the high clutch oil pressure switch is marked.
• Tighten the bolts to the specified torque.
Torque:
Oil pressure switch bolts – 4 N ⋅
⋅⋅
⋅
m (0.4 kgf ⋅
⋅⋅
⋅
m/35 Ib ⋅
⋅⋅
⋅
in)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) – 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
6. Solenoid fixing plate
7. Harness bracket Install the solenoid fixing plate together with the harness
bracket.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Solenoid fixing plate bolt
(A) 4 16 mm (0.63 in) (Gold)
(B) 7 45 mm (1.77 in) (Silver)

13CV20




14CV21



15CV26

8. Harness assembly
Install the harness assembly.


















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UNIT REPAIR (JR405E) 7A4-17
9. Oil strainer Install the oil strainer.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Oil strainer bolt
(C) 9 13 mm (0.51 in) (Silver)
(D) 4 45 mm (1.77 in) (Silver)

16CV40




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7A4-18 UNIT REPAIR (JR405E)
CONTROL VALVE UPPER BODY

09CV02
Legend
1. Manual valve, and pin
2. Retainer plate, spring, and 2-4 brake accumulator
3. Retainer plate, plug, and low and reverse brake fail valve B
4. Retainer plate, plug, spring, and reverse stall valve
5. Retainer plate, spring, and low and reverse brake solenoid accumulator
6. Retainer plate, spring, and pilot valve
7. Retainer plate, spring, and low clutch solenoid accumulator
8. Retainer plate, plug, spring, and low clutch amp valve A


9. Retainer plate, plug, spring, and 2-4
brake fail valve B
10. Retainer plate, sleeve, plug, spring, and lock-up control valve
11. Retainer plate, plug, spring, and 2-4 brake amp valve
12. Retainer plate, plug, spring, and high clutch amp valve
13. Retainer plate, spring, and high clutch solenoid accumulator
14. Control valve upper body
15. Spring
16. Steel ball


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UNIT REPAIR (JR405E) 7A4-19
Disassembly steps
• Remove the 11 steel balls and springs from the control
valve upper body.
244L300005
Legend
1. Steel ball: A – 10 (Silver) B – 1 (Black)

2. Spring
3. Separation plate



• Remove the control valves from the control valve uppe
r
body.
NOTE:
Place the control valve where it will not get mixed up with
the other parts.

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7A4-20 UNIT REPAIR (JR405E)

Inspection
Valve
Inspect each of the valves for denting and other damage.
Spring
Inspect each of the springs for wear and fatigue.

Valve specifications
244L300006












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UNIT REPAIR (JR405E) 7A4-21
No. Valve
nomenclature Diameter
(mm / in) Length
(mm / in) Configuration
1 Manual 12.0 /
0.472 82.0 /
3.228
2 2 – 4 brake
accumulator 15.0 /
0.591 37.5 /
1.476
3 Low and reverse
brake fail (B) 10.0 /
0.394 52.0 /
2.047
4 Reverse stall 8.0 /
0.315 50.0 /
1.969
5 Low and reverse
brake solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
6 Pilot 12.0 /
0.472 38.5 /
1.516
7 Low clutch
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
8 Low clutch amp
(A) 12.0 /
0.472 53.5 /
2.106
9 2 – 4 brake fail
(B) 10.0 /
0.394 39.0 /
1.535
10 Lock-up control 12.9 /
0.508 57.5 /
2.264
11 2 – 4 brake amp 12.0 /
0.472 53.5 /
2.106

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7A4-22 UNIT REPAIR (JR405E)
12 High clutch amp 12.0 /
0.472 53.5 /
2.106
13 High clutch
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter (mm / in) Linear
diameter (mm / in) Number of
coils
1 Manual ---- ---- ---- ----
2 2 – 4 brake accumulator 43.9 / 1.728 11.0 / 0.433 2.0 / 0.079 13.1
3 Low and reverse brake fail (B) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
4 Reverse stall 31.5 / 1.240 7.0 / 0.276 1.0 / 0.039 12.8
5 Low and reverse solenoid brake
accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
6 Pilot
32.0 / 1.260 11.0 / 0.433 1.3 / 0.051 9.2
7 Low clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
8 Low clutch amp (A) 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
9 2 – 4 brake fail (B) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
10 Lock-up control 27.0 / 1.063 14.0 / 0.551 1.1 / 0.043 5.7
11 2 – 4 brake amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
12 High clutch amp 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
13 High clutch solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
Reassembly steps
• Coat the parts with ATF before installing them.
• Install the control valve to the upper body.
• Install the 11 steel balls and springs to the upper body.



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UNIT REPAIR (JR405E) 7A4-23
CONTROL VALVE LOWER BODY

10CV11
Legend
1. Retainer plate, spring, and steel ball
2. Retainer plate, plug, spring, and pressure regulator valve
3. Retainer plate, spring, and high clutch accumulator
4. Retainer plate, plug, low and reverse brake fail valve A, and spring
5. Retainer plate, plug, spring, and fail valve
6. Retainer plate, plug, low and reverse brake amp valve, and spring
7. Oil pressure switch
8. Oil filter
9. Solenoid
10. Line pressure solenoid
11. Lock-up solenoid


12. Harness bracket
13. Solenoid fixing plate
14. Harness assembly
15. Retainer plate, plug, spring, and 2-4 brake fail valve A
16. Retainer plate, plug, spring, and low clutch amp valve B
17. Retainer plate, spring, and torque converter relief valve
18. Oil strainer
19. Control valve lower body
20. Retainer plate, spring, and 2-4 brake solenoid accumulator
21. Oil pressure switch


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ISUZU KB P190 2007