start ISUZU KB P190 2007 Workshop Repair Manual

ON-VEHICLE SERVICE (AW30–40LE) 7A3-19
ATF Replacement
Inspection
NOTE: Do not overfill.
1. Remove the drain plug from oil pan and drain the
fluid.





RUW 17ASH013401
2. Reinstall the drain plug securely.
Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅
⋅⋅
⋅
m/14 Ib ⋅
⋅⋅
⋅
ft)
3. W ith the engine OFF, add new fluid through the fille
r
tube.



Drain and refill 5.2 liter
Dry fill 8.7 liter
Fluid Exxon Mobil ATF-3309
4. Start the engine and shift the selector into all
position from “P" through “L", and then shift into “P".
5. W ith the engine idling, check the fluid level. Add fluid up to the “COLD" level on the dipstick.
6. The ATF level must be checked again for correct level with the “HOT" level.
NOTE: To prevent fluid leaks, the drain plug gasket
must be replaced each time this plug is removed.



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ISUZU KB P190 2007

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.













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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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7A3-22 ON-VEHICLE SERVICE (AW30–40LE)
Input and Output Revolution Sensor
Inspection
1. Disconnect the input and output revolution sensor
connector.
2. Use an ohmmeter to measure the resistance between terminals 1 and 2.
Standard resistance
Input revolution sensor: 560 – 680
Ω
ΩΩ
Ω (at 20
°
°°
°
Cor
68 °
°°
°
F)
Output revolution sensor: 560 – 680
Ω
ΩΩ
Ω (at 20
°
°°
°
C
or 68 °
°°
°
F)





F07RY00018



Power and 3rd Start Switch
Inspection
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Pry out the switch from the floor console.
4. Disconnect the harness connector.
5. Check continuity between terminals (5) and (6) at third (3rd) position.
6. Check continuity between terminals (3) and (6) at power (PW R) position.
7. Replace the power and 3rd start switch if the result of inspection is abnormal.
8. Connect the harness connector.
9. Connect the negative battery cable.
10. Remove the wheel blocks.
238R300003




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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



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10. Disconnect the fuel pipe clip (1).




1

RTW 77ASH001301


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7A3-42 ON-VEHICLE SERVICE (AW30–40LE)
11.Disconnect the shift cable (1) from the
transmission side.




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12.Disconnect the transmission harness connector (2)
and two clips (1).




2
1
1


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13.Remove the oil level gauge and upper guide tube.

14.Remove the fuel pipe bracket bolt (1) on clutch
housing lower left side.





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15.Disconnect the shift cable bracket on the
transmission side.
16.Disconnect the starter assembly with shift cable bracket.
17.Remove the ATF pipe bolt (1).




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18.Disconnect two ATF pipes.

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ON-VEHICLE SERVICE (AW30–40LE) 7A3-45
3. Remove a engine jack.
4. Remove a transmission jack.
5. Connect the two fuel pipe clips (1) on the transmission crossmember left side.




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6. Install the torque converter bolts.
Torque: 29 N ⋅
⋅⋅
⋅
m(3.0 kgf ⋅m/22 lb ⋅ft)
NOTE: Do not reuse the torque converter bolts.
7. Install the under cover(1). Torque: 8 N ⋅
⋅⋅
⋅
m(0.8 kgf ⋅m/69 lb ⋅in)





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8. Connect two ATF pipes.
Torque: 44 N ⋅
⋅⋅
⋅
m(4.5 kgf ⋅m/33 lb ⋅ft)
9. Install the ATF pipe bolt (1).




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10.Connect the starter assembly with shift cable
bracket.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)
11.Connect the shift cable bracket on the transmission side.
12.Install the fuel pipe bracket bolt (1) on clutch housing lower left side.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)





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13.Install the oil level gauge and upper guide tube.



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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


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




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16.Connect the fuel pipe clip (1).




1

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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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ISUZU KB P190 2007

7A4–2 UNIT REPAIR (AW30–40LE)
Major Components (1)
Major Components (1) and Associated parts
RTW77AMF003801
EndOFCallout
Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
Legend (1) Torque converter
(2) Neutral start switch
(3) Elbow
(4) Oil temperature sensor
(5) Breather hose (6) Output revolution sensor
(7) Adapter housing
(8) Transmission assembly
(9) Select lever
(10) Input revolution sensor

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–3
3. Remove the neutral start switch (Mode switch). Unstake the lock washer.
 Remove the nut and bolt, and then remove the
neutral start switch.
 Remove the lock washer.
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4. Remove the two elbows from transmission case.
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5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4 ×4).
9. Remove the output revolution sensor (4 ×2).
10. Remove the speedometer sensor, speedometer driven gear and plate (4 ×2).
11. Remove the extension housing (4 ×2).
12. Remove the adapter housing (4 ×4). 13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (1)
Holding fixture base: 5-8840-0003-0 (2)
RTW77ASH003301

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7A4–4 UNIT REPAIR (AW30–40LE)
Components (1)
Reassembly
1. Install a new gasket and the extension housing(4×2) to the transmission case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
2. Install the speedometer driven gear, plate, and speedometer sensor (4 ×2).
Torque:
Plate bolt – 15 N·m (1.5 kgf·m/11 Ib ·ft)
Speedometer sensor – 25 N·m (2.5 kgf·m/18 Ib ·ft)
3. Install the adapter housing (4 ×4).
 Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
241RY00020
 Apply liquid gasket (TB1281 –B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
 Install the adapter housing to the transmission
case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
4. Install the neutral start switch.  Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
 Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
 Install the lock washer and nut.
Torque: 7 N·m (0.7 kgf·m/61 Ib ·in) 
Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (1.3 kgf·m/113 Ib ·in)
 Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW17ASH013601
5. Install the oil temperature sensor to the transmission case.
Torque: 15 N·m (1.5 kgf·m/11 Ib ·ft)
RTW77ASH003501

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