Isuzu KB P190. Service manual — part 989

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 (4WD), refer to 7D Transfer Case and Adaptor Housing:

• neutral

switch,

• 2WD – 4WD shift actuator switch,

• speed

sensor.

N O T E

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 4WD
Indicator will light).

5

Remove the following components:

a

Front and centre exhaust assemblies, refer to 6F Exhaust System.

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 Wiring 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.

Automatic Transmission – 4L60E – On-vehicle Servicing

Page 7C4–45

Support the transmission when removing the
attaching bolts to avoid damage to the torque
converter and flexplate. Do not have the
transmission hanging.

N O T E

The bolts attaching the torque converter housing
are facing forward except for the bolt in position ℑ
which is facing rearward.

16

With the transmission supported, using a long socket extension, universal joint and suitable size socket, remove
the bolt (1), nine places, attaching the torque converter housing to the engine, in the reverse order of the torque
sequence shown in

within Figure 7C4 – 62.

The transmission assembly must not be
allowed to rest on its oil pan.

17

Support the transmission assembly on a suitable cradle and secure it. Place a suitable support under the engine oil
pan rail to support the engine after the transmission has been removed.

18

Remove the transmission assembly, disengaging the filler tube attached to the engine.

19

Remove the bolt (3) and torque converter cover (4) on the transmission right-hand side, remove the bolt (5) and
torque converter cover (6) on the transmission left-hand side.

20

Install a suitable holding tool to prevent the torque converter from becoming dislodged.

21

If required on 4WD vehicle, remove the transfer case, refer to 7D Transfer Case and Adaptor Housing.

Figure 7C4 – 62

Automatic Transmission – 4L60E – On-vehicle Servicing

Page 7C4–46

Reinstall

1

If required on 4WD 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.

N O T E

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.