Replacing the transmission pan gasket on an Isuzu D-Max (KB P190) involves a series of steps that require careful attention to detail and the right tools and materials. click here for more details on the download manual…..

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Below is a comprehensive guide to help you through the process.

### Tools and Materials Needed:

1. **Tools:**
– Socket set (including ratchet and extensions)
– Torque wrench
– Screwdrivers (flathead and Phillips)
– Pliers
– Oil catch pan
– Gasket scraper or razor blade
– Torque specifications sheet
– Clean rags or shop towels
– Funnel

2. **Materials:**
– Replacement transmission pan gasket (specific to Isuzu D-Max P190)
– Transmission fluid (check manual for specifications)
– Cleaning solvent (like brake cleaner or degreaser)
– RTV silicone (if needed for additional sealing)

### Safety Precautions:

– Ensure the vehicle is on a level surface.
– Use Jack stands if lifting the vehicle.
– Wear gloves and safety glasses.

### Step-by-Step Process:

#### 1. Preparation

– **Park the Vehicle**: Ensure the vehicle is parked on a flat surface, and engage the parking brake.
– **Disconnect the Battery**: Remove the negative terminal from the battery to prevent any electrical issues while working.

#### 2. Drain the Transmission Fluid

– **Locate the Drain Plug**: Underneath the vehicle, locate the transmission pan. Look for the drain plug (if equipped).
– **Drain Fluid**: Place the oil catch pan under the transmission pan. Remove the drain plug using the appropriate socket and allow the fluid to drain completely. If there is no drain plug, you may need to remove the pan to drain the fluid.

#### 3. Remove the Transmission Pan

– **Unscrew Bolts**: Using the socket set, remove the bolts securing the transmission pan to the transmission. Work your way around the pan in a crisscross pattern to minimize bending.
– **Carefully Remove the Pan**: Once all bolts are removed, gently tap the pan with a rubber mallet (if stuck) and carefully lower it. Be cautious of any remaining fluid inside.

#### 4. Clean the Transmission Pan and Surface

– **Clean the Pan**: Use a cleaning solvent and a rag to clean the inside of the transmission pan thoroughly. Remove any debris or metal shavings.
– **Scrape Old Gasket Material**: Use a gasket scraper or razor blade to remove the old gasket material from both the pan and the transmission surface. Be careful not to scratch the surfaces.

#### 5. Install the New Gasket

– **Position the New Gasket**: Place the new gasket onto the transmission pan. Ensure that it is aligned correctly with the bolt holes.
– **Use RTV silicone (if needed)**: If the manufacturer recommends, you can apply a thin layer of RTV silicone to one side of the gasket for additional sealing (usually on the transmission side).

#### 6. Reattach the Transmission Pan

– **Align the Pan**: Carefully lift the transmission pan and align it with the bolt holes.
– **Hand Tighten Bolts**: Insert the bolts and hand tighten them to hold the pan in place.
– **Torque the Bolts**: Using a torque wrench, tighten the bolts in a crisscross pattern to the manufacturer’s specified torque settings (check the service manual for the exact torque specifications).

#### 7. Refill Transmission Fluid

– **Replace the Drain Plug**: If you drained the fluid through a plug, reinstall and tighten it securely.
– **Add Transmission Fluid**: Locate the transmission dipstick tube (if applicable). Use a funnel to add new transmission fluid through the dipstick tube. Check the owner’s manual for the correct type and amount of fluid.
– **Check Fluid Level**: Start the engine and let it idle. Shift through all gears and check the fluid level using the dipstick. Add more fluid if necessary until it reaches the correct level.

#### 8. Final Checks

– **Reconnect the Battery**: Reattach the negative terminal to the battery.
– **Check for Leaks**: Start the vehicle and let it run for a few minutes. Check under the vehicle for any signs of leaking fluid.
– **Test Drive**: Take the vehicle for a short drive to ensure proper operation and check the fluid level once more.

### Conclusion

Replacing the transmission pan gasket on an Isuzu D-Max KB P190 can be a manageable task if approached methodically. Ensure that you have the correct tools and parts, follow safety precautions, and consult the vehicle’s service manual for specific details related to your model. Properly maintaining your vehicle’s transmission can lead to a longer lifespan and better performance.
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