BULLETIN NUMBER:
IB18-X-002B

IMPORTANT SERVICE
INFORMATION FOR:
 SERVICE MANAGER
 SERVICE ADVISOR
 TECHNICIAN
 PARTS DEPARTMENT
 WARRANTY PERSONNEL

ISSUE DATE:
SEPTEMBER 2018
GROUP:
MISCELLANEOUS

ENGINE AND TRANSMISSION REPLACEMENT
CONTACT TECHNICAL ASSISTANCE LINE (TAL)
AFFECTED VEHICLES


1999MY to current Isuzu vehicles equipped with diesel engines



2012MY to current Isuzu Stripped Chassis (Reach Vans)



2018MY to current Isuzu FTR Vehicles



2003MY to current Isuzu vehicles equipped with 6.0 L gas engines

This bulletin supersedes information bulletin IB18-X-002A. This bulletin is being revised to
add Caller Preparedness Engine/Transmission Form. Please discard previous bulletin
IB18-X-002A.
INFORMATION
IMPORTANT: Effective June 1, 2018 – The IQC process will be transferred to Isuzu
Technical Assistance. As of June 1, 2018, please contact the Isuzu Technical
Assistance Line at 1-877-ISUZUCV (1-877-478-9828), Prompt 3, prior to replacing
engines or transmissions that are believed to be covered by the Isuzu new vehicle
warranty, Isuzu parts warranty, Gold Star used truck warranty and/or all extended
powertrain warranties offered by Isuzu as well as over-the counter engine and
transmission assembly replacements.
We ask you to call the TAL so that we may obtain faster and more accurate quality information on failed
engines and transmission assemblies and improve the reliability of OEM and service replacement engine
and transmission assemblies.
For the Affected Vehicles, this bulletin applies to all OEM and remanufactured engine and transmission
assemblies to be replaced under the Isuzu new vehicle warranty, Goodwill, Isuzu parts warranty, Gold Star
used truck warranty and/or all extended powertrain warranties offered by Isuzu, as well as all over-thecounter engine and transmission assembly replacements.
Component Type

Description
4JJ1-TC (3.0L)

Diesel Engine

4HE1-TC (4.8L)
4HK1-TC (5.2L)
6HK1-TC (7.8L)

Gasoline Engine
Automatic Transmission

6.0L
All AISIN
6L-90E (N-Gas)

For over the counter sales of engine and transmission assemblies for the Affected Vehicles, the selling
dealer is required to contact the Isuzu Technical Assistance Line (TAL) prior to replacement. The selling
dealer is required to provide purchasing documentation with serial numbers as well as information listed
below.
NOTE: All information and measurements are to be made before assembly replacement.
Please be prepared to provide the following information:
For All Affected Engine and Transmission Requests






Dealer Information (contact name, contact number, FAX number, E-mail address).
Vehicle Information (17-digit VIN, model year, mileage, body type, warranty start date).
Failure Information (RO#, RO date, customer name, customer complaint, towing history).
Maintenance/Repair History (date, mileage, and description of complete repair history;
Electronically attach documents as necessary). Maintenance records are to be e-mailed to
the Isuzu Technical Assistance Line (TAL) at [email protected].
Diagnostics (Technician diagnostics, road test, reason for replacement/repair, DTCs,
modifications/accessories/PTO, serial number, sensor reading, ATF leakage and location,
fluid level and condition, parts replacement information, engine performance, road condition).

Additional Information Required for Over the Counter Sales:


Provide purchasing documentation with engine and/or transmission serial numbers.

IMPORTANT: Document engine and/or transmission serial numbers on invoice at time of sale.
Additional Information Required for Diesel Engines Equipped with DPF:


Perform Health Report/Mimamori ECU Download and Synchronization.

IMPORTANT: Health Report results will not be used for denial of customer warranty repair, but
failure to perform this procedure may result in delay of dealer warranty claim payment.
Additional Information Required for Transmission Requests:




Transmission Line Pressures (at idle).
Stall Test (at D-Range, at R-Range) results.
Replacement Parts Information other than A/T ASM (e.g., TCM, etc.)

Additional Information Required for AISIN 6-speed (A460/A465) Transmission Requests:


TCM Freeze Frame Data Download and Synchronization (see details below).

In some cases, additional information may be requested by TAL to better understand the condition and
nature of the failure. Once all information is collected TAL will provide the recommended repair method,
decide whether to approve warranty repair, and forward the information to the DSPM. In some cases TAL
may determine that warranty approval needs to be decided by the DSPM. In these cases the DSPM will
be notified by TAL. The DSPM will call the contact person, review the failure, diagnosis and warranty
coverage. It is important that the TAL Case number be added into the warranty claim.

AISIN TCM FREEZE FRAME DATA
For Aisin automatic transmission replacement requests capture and synchronize TCM Freeze Frame Data
as described below.
IMPORTANT: IDSS must be connected to the internet in order to complete this process.
1. Confirm your computer is connected to the internet and open IDSS.

2. Select your subject vehicle and navigate to the following location; Scan Tool/DTC/Transmission
DTC. Once in this location you will be able to select Freeze Frame/Failure Records.
3. Select Freeze Frame/Failure Records and follow the prompts.
a. Input the RO number. This number must match the RO provided to the TAL case.

IMPORTANT: Inputting the incorrect or mismatched RO numbers will cause a delay in the TAL
process. Be sure the RO number used for Freeze Frame Data Capture and Synchronization is
identical to the RO used for the TAL case request.
4. IDSS will confirm when “Freeze frame information has been sent”.

DIAGNOSTIC INFORMATION
Below is a list of bulletins and common check points that may be helpful. These items should be
reviewed if applicable.
ENGINE:
IB12-J-005C Intake Manifold Inspection/Replacement After Severe Engine Damage
IB14-J-002 Oil in the Intake - Turbocharger Inspection
IB16-J-002 Possible Causes for Engine Oil Diluted With Diesel Fuel
IB18-J-001 Engine Noise and or Misfire
06-06-02-012 Information on Not Re-Using Engine Block Heater
06-06-04-061 Engine Oil Pressure Warning Light Illuminated, Engine Oil Seepage/Leaking Onto
Ground
05-06-04-033A Malfunction Indicator Lamp (MIL) On, DTC P0340 (Camshaft Position Sensor)
Set (Inspect and Repair Camshaft Position Sensor Wiring)
04-06-93-001A Information on Isuzu Diesel Engine Turbocharger Diagnostics
01-06-04-048A Availability of New Fuel Injection Pump Oil Supply Pipe for Replacement after
Removal
Cylinder Compression Testing
Valve Adjustment Procedure
Crankshaft End Play
TRANSMISSION:
07-07-30-013 AISIN Automatic Transmission “Slip Control System” (SCS) New Fluid Reminder
IB07-K-001F AISIN Automatic Transmission Service Reminder
05-07-30-030A Use of Shrink Tubing Around Transmission Fluid Level Indicator (Dipstick) Tube
Joint to Avoid Water Intrusion

IB10-K-001A Replacement of Output Flange Nut when Servicing Transmission
03-07-30-060B Automatic Transmission Oil Cooler Flushing and Flow Testing
02-07-30-025B Harsh Shifting, Delayed up shifts with Possible CHECK TRANS Lamp Illuminated,
Possible DTC 21 Set (Perform TPS Relearn Procedure)
SB10-K-001F Approved 6-Speed AISIN Automatic Transmission On-Vehicle Internal Repairs

CORE RETURN PROCEDURE
US DEALERS ONLY
In SOME cases, TAL may request the failed engine/transmission be returned for tear-down investigation.
Please follow the procedure below to properly return these requested assemblies.
If the
engine/transmission core is not request by TAL, return the core through the normal core return process as
outlined by AIPDN.
NOTE: BE SURE TO COMPLETELY FILL OUT THE RETURN CORE TAG.
Return Procedure for TAL-Requested Assemblies for Failure Analysis
IMPORTANT: Engines/Transmissions requested by the TAL will be picked up by YRC Freight at NO
COST to the dealer. Be sure that the engine/transmission is ready for pick-up at the requested
time.
1. Verify the TAL case number matches up to the VIN of the vehicle and the serial number of the
Engine and/or Transmission.
2. Drain the core, place it in the same plastic bag the new component arrived in. Securely fasten
engine/transmission into shipping container. (For engines also include an oil sample.) Include
a copy of all paperwork (RO and TAL case) inside the shipping container for return.
3. Paperwork will be received by Fax or E-Mail for shipment from Isuzu. This will include a prepaid
Bill of Lading (BOL) and a copy of the TAL case.
4. When the package is ready for pick-up the dealer is to contact YRC Freight. YRC Freight
contact information is listed in the BOL. Engines and transmissions need to be shipped within
ten (10) days of filing warranty claims.
5. Contact Isuzu with the tracking number. Isuzu contact information is listed on the BOL and
below.



Engines, 6L90 Transmission:
Maurice Bowie: 657-295-4011, [email protected]
Transmissions, Aisin only:
Rodney Harada: 714-935-9321, [email protected]

IMPORTANT: Be sure to ship to proper destination, as requested on BOL to ensure prompt core
credit.
IMPORTANT: Dealers should not under any circumstances submit for engine/transmission core
credit (for a core collected by the TAL) through the warranty system.
CANADA DEALERS
All engine/transmission cores should be returned through the normal core program as outlined by AIPDN.

WARRANTY SUBMISSION
When submitting warranty claims, be sure to add the TAL case number in the TAL case number field.
Labor Operation

Description

Time Allowance

K7000

A/T Transmission Assembly – R&R

Refer to the Labor Time Guide

J1840

Engine Long Block Assembly – R&R

Refer to the Labor Time Guide

Caller Preparedness Engine/Transmission Form
Email all supporting documents such as maintenance records and pictures to:
[email protected]
VIN #

Engine/Trans Serial No:
☐

Health Report/TCM Freeze Frame

☐ Miles ☐ KM

Speed at Failure:

Road Condition: ☐ Highway ☐ City ☐ Downhill ☐ Level ☐ Uphill ☐ Unknown
Did the customer state they were able to safely stop?

☐ Yes ☐ No

Was the vehicle towed In? ☐ Yes ☐ No Miles Towed:

Towed From:

□ Active Traffic Lane ☐ Home/Business ☐ Other Parking Lot ☐ Side of Road ☐ Other
How was it towed:

☐ Flatbed ☐ From Rear ☐ From Front with Propeller Shaft Installed
□ From Front with Propeller Shaft Removed

Oil Level: ☐ Below Minimum

☐ Minimum

Oil Level; (Trans Hot): ☐ Below Minimum
Oil Condition: ☐ Good/Clean

☐ Acceptable
☐ Minimum

☐ Milky/Colored

☐Full

☐ Acceptable

☐ Dark/Dirty

☐ Overfull
☐Full

☐ Overfull

☐ Diesel Smell/Dilution

Disassembly by Dealer (Please check all that apply)
□ Cylinder Head

☐ Oil Pan

□ Oil Filter

☐ Valve Body ☐Front Pump

Engine Only

☐Rod Bearings

☐ Flywheel housing

☐Front Cover

☐Main Bearings

Performance Normal: ☐ Yes ☐ No

Accessory Drive Modified: ☐ Yes ☐ No

Trans Only

☐Fuel Injectors

PTO: ☐ Yes

Oil Leak? ☐ Yes ☐ No

☐ No

Accessory Drive Modification Description:

PTO Description:

Leak Location: ☐ Breather Hose ☐ Cooler Pipe ☐ Dip Stick

☐Front Seal ☐ Rear Seal ☐ Oil Pan ☐ Other

Pressure in Drive:

Replacement Parts: (Shift Solenoid, TCM, Internal Harness…ETC.)

Core Administrator Name:
Core Administrator Email:

Pressure in Reverse: