start ISUZU KB P190 2007 Workshop Repair Manual

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–16
8 Slide the cover (3) in the direction shown by the
arrow (1).
9 Using a small flat blade screwdriver, move the lock piece (4) from the position indicated by the arrow (2).
Continue to move the lock piece until the adjuster (5)
position begins to change.

Figure 7C4 – 12
10 Connect the selector cable to the transmission external manual shaft linkage.
11 Insert the lock piece in the adjuster to engage with the serrated cable end (cable length adjustment).
12 Slide the cover (1) on the adjuster and secure the lock piece.

Figure 7C4 – 13
13 Install the heat shield (7) and tighten the attaching screws (1 and 6) to the correct torque specification, refer to Figure 7C4 – 10.
Heat shield front attaching screw
torque specification ............................................ 25.0 Nm
Heat shield rear attaching screw torque specification ..............................................9.0 Nm
14 Move the selector lever to the P position and press the selector lever knob button five times.
15 Ensure the selector lever moves smoothly to each of its positions.
16 Check if the shift position indicated by the selector lever and the actual shift position are the same, rectify if required.
17 Lower the vehicle to the ground. Ensure the engine can only be started with the transmission selector lever in Park or Neutral position and the back-up lamps work correctly. If required, adjust the neutral start and back-up lamp
switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
18 Ensure the gear selection operates correctly.
19 Install the front and rear console, refer to 10 Cab.
3.4 Neutral Start and Back-up Lamp Switch
Remove
1 Position the transmission selector lever to the P position.
2 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–17
3 Remove the three attaching screws (1 and 2) and the
heat shield (3).
4 Hold the transmission manual shaft linkage (4) with an adjustable wrench and remove the linkage attaching
nut (5).
5 Carefully remove the manual shaft linkage and selector cable from the transmission manual shaft (6).
6 Prise the connector position assurance (CPA) securing pin (7) from the neutral start and back-up
lamp switch (8) taking care not to break the pin in the
process. Disconnect the connector (9) from the switch
assembly by pulling down the release bar (10).
NOTE
The connector will automatically disconnect at
the same time the release bar is withdrawn.
7 Remove the attaching screw (11) and slide the switch assembly over the transmission manual shaft to
remove it.
Figure 7C4 – 14
Reinstall
1 Slide the neutral start and back-up lamp switch (8) over the transmission manual shaft (6) and reinstall the two
attaching screws (1 and 11), tighten them finger tight until the adjustment process has been completed, refer to
Figure 7C4 – 14.
2 Install the manual shaft linkage (4) and the attaching nut (5). Hold the linkage with an adjustable wrench and tighten the nut to the correct torque specification.
Manual shaft linkage attaching nut
torque specification ............................................ 25.0 Nm
3 Install the connector (9) but do not reinsert the CPA securing pin (7) at this stage.
4 Check the shift selector linkage operation and adjust as required, refer to 3.2 Shift Selector Assembly.
5 Check and adjust as required the neutral start and back-up lamp switch as described in this Section, refer to Adjust.
Adjust
1 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
2 If required, loosen the neutral start and back-up lamp switch (8) as follows, refer to Figure 7C4 – 14: a Remove the three attaching screws (1 and 2) and the heat shield (3).
b Prise the connector position assurance (CPA) securing pin (7) from the neutral start and back-up lamp switch taking care not to break the pin in the process.
c Disconnect connector (9) from the switch assembly by pulling down the release bar (10).
NOTE
The connector will automatically disconnect at the
same time the release bar is withdrawn.
d Loosen the screw (11) attaching the switch and refit the front screw (1) keep them finger tight.
e Reinstall the connector (9) but do not reinsert the CPA securing pin at this stage.
3 Rotate the neutral start and back-up lamp switch back and forth until a central position is attained and then lightly tighten the front screw (1) to prevent the switch from rotating.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–18

Ensure the four wheels are off the ground
before performing the starting test.
4 W ith the ignition switched to the ON position, check if the engine can only be started in the Park and Neutral shift selector positions and ensure the back-up lamps illuminate when Reverse is selected. A further minor adjustment
may be required to achieve this state.
NOTE
To gain access to the rear attaching screw (11) it
will be necessary to remove the connector.
5 After the switch has been adjusted, tighten the rear attaching screw (11) to the correct torque specification. Neutral start and back-up lamp switch
attaching screw torque specification .................. 25.0 Nm
6 Reinstall the connector and the CPA securing pin.
7 Remove the switch front attaching screw (1).
8 Install the heat shield (3) and tighten the attaching screws (1 and 2) to the correct torque specification.
Heat shield front attaching screw
torque specification ............................................ 25.0 Nm
Heat shield rear attaching screw torque specification ..............................................9.0 Nm
9 Lower the vehicle to the ground and re-check the operation of the neutral start and back-up lamp switch. The vehicle must start only with the shift selector in the Park or Neutral positions and the back-up lamps should only
illuminate when Reverse is selected.
3.5 Vehicle Speed Sensor
NOTE
For the speed sensor fitted to four wheel drive
vehicles (4WD), refer to 7D Transfer Case and
Adaptor Housing.
Remove
1 Raise the vehicle and support in a safe manner, refer
to 0A General Information for the location of support
points.
2 Disconnect connector (1) from the vehicle speed sensor (2).
3 Remove the bolt (3) attaching the speed sensor to the transmission extension housing.
4 With a pulling and turning motion, remove the speed sensor and O-ring seal (4) from the transmission
extension housing, discard the O-ring.
Figure 7C4 – 15

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–19
Reinstall
1 Lubricate a new O-ring seal with petroleum jelly and install it to the vehicle speed sensor.
2 Install the speed sensor to the transmission extension housing.
3 Install the attaching bolt and tighten to the correct torque specification.
Vehicle speed sensor attaching bolt
torque specification ............................................ 12.0 Nm
4 Connect the connector to the speed sensor.
5 Lower the vehicle to the ground.
3.6 Manual Shaft Oil Seal
Replace
NOTE
This procedure requires the use of special tool
No. AU583.
1 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
2 Remove the neutral start and back-up lamp switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
3 Assemble the seal remover, Tool No. AU583-3 (1) by installing the remover nut, Tool No. AU583-4 (2) with
its threaded inner diameter closest to the hexagonal
head of the seal remover tool. Install the nut up to the
hexagonal head.
4 Install the assembled seal remover tool over the manual shaft (3) engaging the tapered thread end (4)
into the seal.

Do not over tighten the seal remover tool in
the seal.
5 Rotate the hexagonal head of the seal remover tool clockwise, until the thread grips the steel shell of the
seal.
Figure 7C4 – 16
6 W hile holding the hexagonal head of the seal remover tool (1) rotate the remover nut (2) clockwise, until it
contacts the transmission case.
7 Continue rotating the remover nut until the seal is pulled into the remover nut cavity.
8 Remove and discard the seal.
Figure 7C4 – 17

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–20
9 Install the seal protector, Tool No. AU583-1 (1) into
one of the two plastic seal installers, Tool No.
AU583-2 (2).
NOTE
Two plastic seal installers are required because
of the restricted space between the end of the
manual shaft and the floor pan.
10 Lubricate the lip of a new seal (3) with clean automatic transmission fluid and install it over the seal protector
sleeve, with the steel casing facing the installer tool.
11 Install the seal protector with the new seal and installer tool over the manual shaft (4) and up to the
transmission case.

If the seal protector sleeve jams on the
manual shaft, the flats on the shaft locating
the selector lever will be burred. Use a fine
file to remove any burrs and then proceed.
12 Fit the second plastic seal installer over the manual shaft until it seats against the first installer.
13 Install the manual shaft linkage attaching nut (5) and tighten it to drive the seal in position into the
transmission case.
14 Remove the seal installer and protector tools from the manual shaft.
Figure 7C4 – 18
15 Reinstall the neutral start and back-up lamp switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
16 Lower the vehicle to the ground and as required, check and top up the automatic transmission fluid level, refer to 2.1 Transmission Fluid.
3.7 Transmission Support and Mount
Remove
1 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
2 Support the transmission with a Jack, do not place the support underneath the extension housing or the oil pan, refer to Figure 7C4 – 19.
3 Remove the clip (1) holding the fuel feed and fuel vapour lines on the transmission support (2).
4 Remove the bolt (3) attaching the heat shield (4) to the transmission support.
5 Remove the two nuts (5) attaching the transmission mount to the support.
6 Remove the four bolts and nuts (6) attaching the transmission support to the under body side rails and remove the support.
7 If required, remove the two bolts (7) attaching the transmission mount (8) to the extension housing and remove the mount.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–30
12 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid leaks
from the oil pan area, refer to 2.1 Transmission Fluid.
3.14 Control Valve Body
Remove
1 Partially remove the control valve body harness until it hangs from the pass-thru connector, refer to
3.13 Control Valve Body Harness.
2 Remove the three long bolts (1) and the two short bolts (2) attaching the transmission fluid pressure
(TFP) manual valve position switch assembly (3),
remove the switch and discard the shield (4).
3 Remove the attaching bolt (5) and the manual detent spring (6).
Figure 7C4 – 37

In the following procedure support the
control valve body before removing the last
bolt.
NOTE
The removal may be more manageable by
removing the bolts in a spiral pattern starting
from the outside, removing the centre bolt last.
4 Remove the fourteen remaining bolts (1) attaching the control valve body.

Figure 7C4 – 38

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–34
9 Fit a new shield (1) to the transmission fluid pressure
(TFP) manual valve position switch (2) and reinstall to
the control valve body.
NOTE
Refer to Figure 7C4 – 40 for bolt dimension and
corresponding location.
10 Reinstall the three long bolts (3) and the two short bolts (4) hand tight only.
11 Reinstall the manual detent spring (5) and the attaching bolt (6) hand tight only.
Figure 7C4 – 45

The control valve body bolts must be
tightened in an outward spiral starting from
the centre. Failure to follow this pattern may
distort the valve body causing the valves to
jam in their bores.
12 Follow the sequence starting from the centre as shown by the arrows to tighten the following bolts to the
correct torque specification:
• fourteen bolts (1) attaching the control valve
body,
• five bolts (2) attaching the transmission fluid
pressure (TFP) manual valve position switch and
• one bolt (3) attaching the manual detent spring.
Control valve body attaching bolt
torque specification ............................................ 12.0 Nm
Transmission fluid pressure (TFP) manual valve position switch attaching bolt torque specification ..................................... 12.0 Nm
Manual detent spring attaching bolt torque specification ............................................ 23.0 Nm
13 Reinstall the control valve body harness , refer to 3.13 Control Valve Body Harness.
Figure 7C4 – 46

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–43

If the verifier disc does not clip into place, the
quick-connect fitting is not engaged, rectify
as required.
10 As a security check, push and clip each verification disc into place over the quick-connect fittings. If difficulty is experienced, repeat the installation process until the verification disc can be clipped into place over the radiator
quick-connect fitting.
11 Snap the outlet cooler line (4) in the clip (5) of the radiator fan shroud.
12 Ensure the routeing of the cooler lines is correct and there is no fouling of the lines.
13 Tighten the screw attaching the cooler lines bracket to the correct torque specifications.
Transmission cooler lines bracket
attaching screw torque specification .................. 23.0 Nm
14 If required, top up the transmission fluid level (cold).
15 Start the engine and check for any fluid leak at the fittings. If a leak is found, stop the engine and rectify the leak.
16 Check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.
3.18 Transmission Assembly
Remove

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 6D1-3
Battery, before disconnecting the battery.
1 Disconnect the battery ground lead.
2 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
3 Remove the heat shield from the neutral start and back-up lamp switch, gently prise the selector cable from the transmission external manual shaft linkage and remove the selector cable from the bracket, refer to
3.3 Selector Cable Assembly.
4 Disconnect the harness connectors from the following:
a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on four wheel drive vehicles (4W D), refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
NOTE
If the battery is connected, avoid turning the
ignition switch to the ON position, as the transfer
case control module (TTCM) must first be
removed (memory to be cleared as Check 4W D
Indicator will light).
5 Remove the following components: a Front and centre exhaust assemblies, refer to 6F Exhaust System.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–44
b Starter motor, refer to 6D1-2 Starting System.
b Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
6 On 4WD vehicle, disconnect the harness two clips from the upper side of the transfer case.
7 From within the starter motor access hole, remove the three bolts (2) attaching the torque converter to the flexplate and discard, refer to Figure 7C4 – 62.
8 Remove the transmission support, refer to 3.7 Transmission Support and Mount.
9 Disconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.

Before lowering the transmission take care of
the following:
• Do not strain the harness and connector
as the connector pins could be
permanently damaged.
• Ensure the inlet manifold does not hit the
firewall.
10 Carefully lower the transmission to provide enough clearance to disconnect the harness connector (1).

Do not wiggle the connector from side to side
during removal as the connector pins could
be permanently damaged.
11 Disconnect the harness connector from the transmission as follows:
a Roll back the dust boot to access the connector.
b Squeeze the widest side of the connector (A) inward and pull it directly upward.
Figure 7C4 – 61
12 Remove the screws attaching the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and W iring Harnesses.
13 Place a suitable sized drip tray underneath the transmission.
14 Remove the transmission cooler lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
15 Disconnect the breather hose from the top of the transmission case.


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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–46
Reinstall
1 If required on 4W D vehicle, reinstall the transfer case, refer to 7D Transfer Case and Adaptor Housing.
2 Ensure the transmission and the engine mating surfaces are clean and free of burrs.
3 Lubricate the torque converter spigot (7) with a small amount of high temperature wheel bearing grease, refer to Figure 7C4 – 62.
4 Install a new filler tube seal into the transmission case.

Support the transmission while installing the
attaching bolts to avoid damage to the torque
converter and flexplate. Do not have the
transmission hanging.
5 Bring the transmission up to the engine, inserting the filler tube and ensuring the locating dowels completely enter the torque converter housing.
6 Reconnect the breather hose to the top of the transmission case.
NOTE
The bolts attaching the torque converter housing
are facing forward except for the bolt in position ℑ

which is facing rearward.
7 With the transmission supported, install the bolt (1), nine places, attaching the torque converter housing to the engine and tighten to the correct torque specification following the sequence shown in
within Figure 7C4 – 62.
Torque converter housing attaching
bolt torque specification .......................... 52.0 – 66.0 Nm
8 Remove the access hole cover plate from the lower surface of the housing and push the torque converter forward to meet the flexplate, then hand start three new bolts (2) before tightening to the correct torque specification.
Reinstall the access hole cover plate.
Torque converter to flexplate attaching
bolt torque specification .......................... 60.0 – 70.0 Nm
9 Reinstall the bolt (3) and torque converter cover (4) on the transmission right-hand side and the bolt (5) and torque converter cover (6) on the transmission left-hand side, tighten the bolts to the correct torque specification.
Torque converter cover attaching
bolt torque specification .......................... 12.0 – 16.0 Nm
10 Reinstall the transmission fluid lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.

Prior to connecting the harness connector to
the transmission, check that all pins and
seals are in sound condition and the dust
boot is not torn or damaged.
11 Reconnect the transmission harness connector to the transmission as follows: a Push straight down on the connector body until a click is heard.
b Reinstall the dust boot ensuring it is correctly located.
12 Attach the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and Wiring Harnesses.
13 On 4WD vehicle, connect the harness two clips from the upper side of the transfer case.

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