Neutral switch ISUZU KB P190 2007 Workshop Manual PDF

7A2-24 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
TRANSMISSION DATA
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle
Operating Conditions: Engine idling/ Engine coolant temperature is between 75 to 85 °C(167 to 185 °F)/
Accelerator pedal is constant/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level
Engine Coolant temperature °C/ °F 75 to 85°C (167 to 185 °F)
Engine Speed RPM 700
Vehicle Speed Km/h / MPH 0
Ignition Voltage V 13.6
Accelerator Pedal Position Signal % 0
Throttle Position % 0
Accelerator Pedal Position Signal
During Cruise Control % 0
Cruise Control
Inactive / Active Inactive
Cruise Control OD Cancel Request ON / OFF OFF
Engine W arm Up Cycle Achieved FALSE / TRUE FALSE
Transmission Shift in Progress Inactive / Active Inactive
Garage Shift Control Inactive / Active Inactive
MIL Request Command ON / OFF OFF
Transmission Check Light ON / OFF OFF
Transmission Oil Temperature Lamp ON / OFF OFF
Power Drive Lamp ON / OFF OFF
3rd Start Lamp ON / OFF OFF
Transmission Fluid Temperature
°C/ °F 70 to 80°C (158 to 176 °F)
AT Input Speed RPM 625
AT Output Speed RPM 0
Transmission Range Park / Reverse /
Neutral / Drive 4 / Drive 3 / Drive 2 / Drive 1 Park
TR Switch P
ON / OFF ON
TR Switch R ON / OFF OFF
TR Switch N ON / OFF OFF
TR Switch D ON / OFF OFF
TR Switch 3 ON / OFF OFF
TR Switch 2 ON / OFF OFF
TR Switch L ON / OFF OFF
Diagnostic Switch Open / Close Open
Brake Pedal Switch ON / OFF OFF
Power Drive Switch ON / OFF OFF
3rd Start Switch ON / OFF OFF
4 W heel Drive Low ON / OFF OFF
Shift Solenoid 1 Command ON / OFF ON
Shift Solenoid 2 Command ON / OFF OFF
TCC Solenoid Engaged / Disengaged Disengaged
Downhill Mode Inactive / Active Inactive
Active Shift Mode Normal Mode /
Power Mode /
3rd Gear Start /
Transfer 4L MODE Hot 1 / Hot 2 /
UPHILL MODE 1 /
UPHILL MODE 2 / Cruise MODE /
W arm Up MODE Normal Mode
Estimated Gear Ratio
:1 7.97 : 1

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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-45

DTC P0707 or P0708 (Flash Code 17)



RTW 77ALF001401

Circuit Description
The neutral start switch gives the signals related to the
selector lever position (PRND32L) to the Transmission
Control Module (TCM). The neutral start switch turns on
when the select lever is shifted to the P, R, N, D, 3, 2 o
r
L position. The neutral start switch, which is connected
to the starter switch circuit, is available only when the
select lever is in the P or N position (Engine run).
The neutral start switch is connected to the
transmission manual shaft and mounted on the
transmission case.

Condition For Running The DTC
All of the following conditions are met.
(1) All of the following conditions are met for 2 seconds or more continuously.
• The supply voltage is more than 10.2 volts and
less than 15.5 volts.
• DTC U2104 is not detecting failure or not
deciding failure.
• DTC U2105 is not detecting failure or not
deciding failure.
• Engine revolution signal is not detecting failure
or not deciding failure.
• The engine revolution is more than 550rpm.

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ISUZU KB P190 2007

7A2-46 TRANSMISSION CONTROL SYSTEM (AW30–40LE)


(2) Not emergency mode.
(3) All of the following conditions are met. • Device Control is not operating.
• Disable Normal Communication service is
receiving enable.
• DTC Clear is not operating.
Condition For Setting The DTC
DTC P0707
All of the following conditions are met for 30 seconds or
more continuously.
• All of the switches are “OFF”.
• Output revolution is more than 30 km/h (19 mph).
• Output revolution sensor is not detecting failure o
r
not deciding failure.
• The engine revolution is more than 1500 rpm.
DTC P0708
The following condition is met at 10 seconds
continuously.
• 2 switches or more are “ON” at the same time.
Action Taken When The DTC Sets
• No 3rd start mode.
• No slope control.
• No coast control.
• No output revolution sensor failure detection.
• No input revolution sensor failure detection.
• Keep oil temperature sensor OPEN failure detection accumulated timer.
• No T/F HI-Low SW failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• No engine torque reduction at stall.
• Regard as D position. (DTC P0707)
• There is a priority in order of D, 3, 2, L, R, N, and P.
(DTC P0708)
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
•
The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.

Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
• Check neutral start switch for proper mounting and adjustment. (Refer to section 7A4 Components (1)
neutral start switch)



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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-47

Circuit/System Testing DTC P0707 or P0708
Step Action Value(s) YES NO
1
W as the On-Board Diagnostics (OBD) System check
performed? — Go to
Step 2 Go to OBD
System Check
2 1. Install a scan tool.
2. Turn “ON” the ignition, with the engine “OFF”.
3. Select each lever position: D, 3, 2, L, N, R and P.

Does each selected transmission position match the
“Transmission Range” display on a scan tool? — Refer to
Diagnostic Aids Go to
Step 3

3 Measure the voltage shifting the select lever every position, between TCM connector terminals and
ground which performed selecting to every position.
1. Turn “OFF” the ignition.
2. Disconnect the TCM connector.
3. Turn “ON” the ignition.
4. Connect the 5-8840-0285-0 DMM to the TCM
connector terminal and ground.

Is the displayed voltage at every position normal? 7~16V Go to
Step 8 Go to Step 4
4 Measure the voltage between terminals the neutral
start switch and ground.
1. Turn “OFF” the ignition.
2. Disconnect the inhibitor switch harness connector.
3. Turn “ON” the ignition.
4. Connect the 5-8840-0285-0 DMM to the each
terminal of the neutral start switch harness
connector E51-3 and ground.
If a problem was found, repair as necessary.

W as the problem found? 7~16V Go to
Step 9 Go to Step 5
5 Measure the resistance shifting the select lever to
every position, between terminal neutral start switch
connector E51-3 and E51 other terminal.
1. Turn “OFF” the ignition.
2. Disconnect the neutral start switch connector.
3. Connect the DMM to the each terminal of the neutral start switch connector E51-3 and E51-5
or E51-2 or E51-6, E51-8or E51-7or E51-9 or
E51-10.
If a problem was found repair as necessary.

W as the problem found? Less than
1
Ω
Go to Step 6 Go to Step 7
6 Replace the neutral start switch.

Is the action complete? — Go to
Step 9 —

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ISUZU KB P190 2007

7A2-48 TRANSMISSION CONTROL SYSTEM (AW30–40LE)

Step Action Value(s) YES NO
7 Measure he resistance between terminal neutral start
switch harness connector E51 and TCM harness
connector C-95.
1. Turn “OFF” the ignition.
2. Disconnect the neutral start switch and TCM connector.
3. Connect the jumper wire tot the neutral start switch harness connector E51-2, E51-5, E51-6, E51-7,
E51-8, E51-9 and E51-10 and good ground.
4. Connect the 5-8840-0285-0 DMM to the each terminal of the TCM harness connector C95-1,
C95-20, C95-8, C95-9, C95-7, C95-19 or C95-18.
If the problem was found repair as necessary.

W as the problem found? Less than
1 Ω

Go to Step 9 Go to Step 8
8 Replace the TCM.
Important: The replacement TCM must be
programmed. (Refer to SPS for procedure.)

Is the action complete? — Go to
Step 9 —
9 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with a scan tool.
3. Turn “OFF” the ignition.
4. Start the engine.
5. Operate the vehicle within the Conditions For Running the DTC. You may also operate the
vehicle within the conditions that you observed
from the Freeze Frame/ Failure Records.

Did the DTC fail this ignition? — Go to
Step 2 Go to Step 10
10 Observe the stored information, Capture Info with a
scan tool.

Are there any DTCs that you have not diagnosed? — Go
to
Diagnostic
Trouble Code (DTC) List Verify repair


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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (AW30–40LE)
TABLE OF CONTENTS

Service Precaution .................................................. 7A3-2
Diagnosis ................................................................. 7A3-3
Basic Troubleshooting ........................................ 7A3-3
Manual Shifting Test ........................................... 7A3-9
Stall Test ............................................................... 7A3-9
Time Lag Test ...................................................... 7A3-10
Hydraulic Test ...................................................... 7A3-11
Road Test ............................................................. 7A3-12
Shift Point Chart and Lock-Up Point Chart ..........7A3-16
Shift Point Chart ................................................... 7A3-16
Lock-Up Point Chart ............................................ 7A3-17
Transmission Fluid Level and Condition ..............7A3-18
Inspection ............................................................. 7A3-18
ATF Replacement ................................................... 7A3-19
Inspection ............................................................. 7A3-19
Neutral Start Switch (Mode Switch) ......................7A3-20
Inspection ............................................................. 7A3-20
Removal ................................................................ 7A3-20
Installation ............................................................. 7A3-20
Brake Signal ............................................................ 7A3-21
Inspection ............................................................. 7A3-21
Input and Output Revolution Sensor ....................7A3-22
Inspection ............................................................. 7A3-22
Power and 3rd Start switch ....................................7A3-22
Inspection ............................................................. 7A3-22
Solenoid .................................................................... 7A3-23
Inspection ............................................................. 7A3-23
ATF Temperature Sensor ......................................7A3-24
Inspection ............................................................. 7A3-24

Select Lever ....................................................... 7A3-25 Remove or Disconnect .......................................7A3-26
Install or Connect ................................................ 7A3-26
Shift Cable .......................................................... 7A3-28 Remove or Disconnect .......................................7A3-28
Install or Connect ................................................ 7A3-29
Torque Specifications ......................................... 7A3-30
Transmission Control Module (TCM) ...................7A3-31
Removal ............................................................... 7A3-31
Installation ............................................................ 7A3-31
Shift Solenoid and Lock-Up Solenoid ..................7A3-32
Removal ............................................................... 7A3-32
Installation ............................................................ 7A3-33
Valve Body Assembly and Pressure Control Solenoid ................................................. 7A3-34
Removal ............................................................... 7A3-34
Installation ............................................................ 7A3-36
Rear Oil Seal (Adapter Housing, 4 ×4) ................. 7A3-37
Removal ............................................................... 7A3-37
Installation ............................................................ 7A3-37
Rear Oil Seal (Extension Housing, 4 ×2) .............. 7A3-38
Removal ............................................................... 7A3-38
Installation ............................................................ 7A3-38
Transmission Assembly .........................................7A3-39
Transmission and Associated Parts .................7A3-39
Removal ............................................................... 7A3-40
Installation ............................................................ 7A3-44
Major Components .............................................. 7A3-49





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7A3-20 ON-VEHICLE SERVICE (AW30–40LE)
Neutral Start Switch (Mode Switch)
Inspection
W ith a circuit tester, make a continuity test on the
neutral start switch with the moving piece set in each
position.













RTW 77ASH003401
Removal
Preparation:
Disconnect negative (–) battery cable.
1. Remove the rear side ATF cooler pipe from the
transmission elbow.
2. Disconnect neutral start switch connector.
3. Unstake the lock washer, and then remove the shaft
nut.
4. Remove the neutral start switch.
Installation
To install, follow the removal steps in the reverse order,
noting the following points;
If a engine starts at any selector position except “N” o
r
“P”, the neutral start switch (mode switch) should be
adjusted.
1. Loosen the neutral start switch bolt and set the shift
selector to the “N" position.
2. Align the groove and neutral basic line.
3. Hold in position and tighten the bolt and nut.
Torque:
Nut – 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 Ib ⋅
⋅⋅
⋅
in)
Bolt – 13 N ⋅
⋅⋅
⋅
m (1.3 kgf ⋅
⋅⋅
⋅
m/113 Ib ⋅
⋅⋅
⋅
in)
4. Lock the nut with the lock washer tubs at two points.



RUW 17ASH013601





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7A3-40 ON-VEHICLE SERVICE (AW30–40LE)
Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
4 ×2 using the 4 ×4 push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands.
3. Remove the drain plug and drain the transmission oil.
4. Remove the front propeller shaft. (4 ×4 only)
NOTE: Apply alignment marks on the flange at both
front and rear sides.
5. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the differential side.







RTW 77BSH000201
6. Disconnect 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
7. Disconnect two harness clips (1) of the transfer
upper side.



1
1


RTW 77ASH001601

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ON-VEHICLE SERVICE (AW30–40LE) 7A3-41
8. Remove the transfer assembly. (4×4 only)
9. Disconnect the input sensor connector (1), ATF temperature sensor connector (3), neutral start
(mode) switch connector (4), output senso
r
connector (5) and clip (2).




RTW 77ASH002101



RTW 77ASH002201






RTW 77ASH002301
10. Disconnect the fuel pipe clip (1).




1

RTW 77ASH001301


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7A3-46 ON-VEHICLE SERVICE (AW30–40LE)
14.Connect the transmission harness connector (2)
and two clips (1).




2
1
1


RTW 77ASH001401
15.Connect the shift cable (1) to the transmission
side.




RTW 77ASH002801

16.Connect the fuel pipe clip (1).




1

RTW 77ASH001301
17.Connect the input sensor harness clip.
18.Connect the input sensor connector (1), ATF temperature sensor connector (3), neutral start
(mode) switch connector (4), output senso
r
connector (5) and clip (2).




RTW 77ASH002101


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