BULLETIN NUMBER:
IB18-X-002F

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

ISSUE DATE:
AUGUST 2024
GROUP:
MISCELLANEOUS

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

1999MY to current vehicles equipped with Isuzu diesel engines



2012 to 2018MY Isuzu Stripped Chassis (Reach Vans)



2003MY and newer Isuzu vehicles equipped with 6.0 L gas engines



2020MY to current Isuzu vehicles equipped with 6.6 L gas engines

This bulletin supersedes information bulletin IB18-X-002E. This bulletin is being revised to
update the model years affected. Please discard previous bulletin IB18-X-002E.
INFORMATION
This bulletin applies to all OEM and remanufactured engine and transmission assemblies, for the affected
vehicles listed above, 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-the-counter engine and transmission assembly replacements.
Component Type

Description
4JJ1-TC (3.0L)
4HE1-TC (4.8L)

Diesel Engine
4HK1-TC (5.2L)
6HK1-TC (7.8L)
6.0L
Gasoline Engine
6.6L
All AISIN
Automatic Transmission

6L-90E
8L-90

NOTE: Cummins engines and Allison transmissions are not warranted by Isuzu. Warranty is
provided through the corresponding manufacturer.
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 the 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 tests, reasons 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 dealer contact person, review the failure, diagnosis and warranty
coverage. It is important that the TAL Case number be added to 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 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-005E Intake Manifold Inspection/Replacement After Severe Engine Damage
IB14-J-002B Oil in the Intake - Turbocharger Inspection
IB16-J-002B 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-001H AISIN Automatic Transmission Service Reminder

IB19-K-002 Use of Shrink Tubing Around Transmission Fluid Level Indicator (Dipstick) Tube Joint
to Avoid Water Intrusion
IB10-K-001C 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-001I 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 requested 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 Email 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 and 8L90 Transmissions:
Maurice Bowie: 657-295-4011, [email protected]
Transmissions, Aisin only:
Rodney Harada: 714-935-9321, [email protected]

IMPORTANT: Be sure to ship to the proper destination, as requested in the BOL to ensure prompt
core credit.
IMPORTANT: Dealers should not under any circumstances submit for engine/transmission core
credit (for a core collected by 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
Preparación de la persona que llama / Formulario de transmission y motores
Moteur de préparation de l’appelant/formulaire de transmission

Email all supporting documents such as maintenance records and pictures to:
Envíe por correo electrónico todos los documentos de respaldo, como registros de mantenimiento e imágenes a:
Envoyez par courrier électronique toutes les pièces justificatives telles que les dossiers de maintenance et les photos
à:

[email protected]
VIN #

Engine/Trans Serial No:
Número de serie del motor / transmisión:
Numéro de série du moteur / de la transmission:

☐

Health Report/TCM Freeze Frame

Velocidad en el de falla:
Vitesse en cas de défaillance :

☐ Highway ☐ City ☐ Downhill

Road Condition:

Condiciones del camino: Carretera
État de la route:
Autoroute

☐ Miles ☐ KM

Speed at Failure:

Informe de salud / Cuadro congelado de TCM
Rapport sur la santé / Arrêt sur image de la TCM

Ciudad
Ville

Cuesta abajo
Une descente

☐ Level

☐ Uphill

☐ Unknown

Nivel
Niveau

Cuesta arriba
Montée

Desconocido
Inconnu

☐ Yes

Did the customer state they were able to safely stop?
¿El cliente dijo que pudo detenerse de manera Segura?

Sí

☐ No
No

Le client a-t-il déclaré qu'il avait pu s'arrêter en toute sécurité ?

Was the vehicle towed In?
¿El vehículo fue remolcado?
Le véhicule a-t-il été remorqué?

□ Active Traffic Lane
Carril de tráfico activo
Voie de circulation active

☐ Yes ☐ No Miles Towed:
Sí
Oui

No
Non

Towed From:

Millas remolcadas:
Miles remorqués:

Remolcado Desde:
Remorqué depuis:

☐ Home/Business ☐ Other Parking Lot ☐ Side of Road
Hogar/Negocio
Maison / Entreprise

Otro estacionamiento
Autre parking

How was it towed:

☐ Flatbed ☐ From Rear

¿Cómo fue remolcado?
Comment était-il remorqué:

Cama plana
À plat

☐ Other

Lado de la carretera
Côté de la route

Otro
Autre

☐ From Front with Propeller Shaft Installed

Desde la parte trasera
De l'arrière

Desde el frente con el eje de la hélice instalado
De l'avant avec l'arbre d'hélice installé

□ From Front with Propeller Shaft Removed
Desde el frente con el eje de la hélice eliminado
De l’avant avec l’arbre d’hélice déposé

Oil Level:
Nivel de aceite:
Niveau d'huile:

☐ Below Minimum
Por debajo del mínimo
En dessous du minimum

☐ Minimum
Mínimo
Le minimum

☐ Acceptable
Aceptable
Acceptable

☐Full
Completo
Plein

☐ Overfull
Demasiado lleno
Trop plein

Oil Level; (Trans Hot):

☐ Below Minimum ☐ Minimum ☐ Acceptable ☐Full

Nivel de aceite; (Transmisión en caliente)
Niveau d'huile; (Transmission à chaud)

Por debajo del mínimo
En dessous du minimum

☐ Good/Clean

☐ Milky/Colored

☐ Dark/Dirty

☐ Diesel Smell/Dilution

Bueno /Limpio
Bon /Propre

Lechoso /Coloreado
Laiteux /Coloré

Oscuro /Sucio
Sombre /Sale

Olor a diesel/Dilución
Odeur de diesel/Dilution

Oil Condition:
Condición del aceite
État de l'huile

Mínimo
Le minimum

Aceptable
Acceptable

Completo
Plein

☐ Overfull
Demasiado lleno
Trop plein

Disassembly by Dealer (Please check all that apply)
Desmontaje por parte del distribuidor (Marque todas las que correspondan)
Démontage par concessionnaire (veuillez cocher toutes les réponses appropriées)

□ Cylinder Head
Cabeza de cilindro
Culasse

□ Oil Filter
Filtro de aceite
Filtre à l'huile

☐ Oil Pan

☐Rod Bearings

Colector de aceite
Carter d'huile

Cojinete de biela
Paliers de bielle

☐ Valve Body

☐Front Pump

Cuerpo de la válvula
Corps de soupape

Bomba delantera
Pompe avant

☐Fuel Injectors

☐Front Cover

Performance Normal: ☐ Yes ☐ No

Solo motor
Moteur seulement

Rendimiento normal:
Performance normale:

Accesorio de accionamiento modificado:
Lecteur accessoire modifie

☐ Yes

Trans Only PTO:
Sólo transmission PTO
Transmission seulement PTO
¿Fuga de aceite?
Fuite d'huile?

Sí
Oui

No
Non

Sello trasero
Joint arrière

Accessory Drive Modification Description: _________
Descripción de la modificación de la unidad accesoria:
Description de la modification du lecteur accessoire:

Descripción de PTO
Description de la prise de force

Leak Location:
Localización de la fuite:
Lieu de fuite:

☐ Other

Colector de aceite
Carter d'huile

Otro
Autre

☐ Breather Hose
Manguera de respiracion
Tuyau de reniflard

(Solenoide de cambio, TCM, Arnés interno…ETC.)
(Solénoïde de décalage, TCM, Harnais interne…ETC.)

Core Administrator Name:
Nombre del administrador de piezas originales:
Nom de l'administrateur de pieces d’origine:

Core Administrator Email:
Correo electrónico del administrador de piezas originales:
Courriel de l'administrateur principal :

☐ Cooler Pipe

☐ Dip Stick

Tubo de entriamiento
Tuyau de refroidisseur

Varilla graduada
Jauge

Pressure in Drive:________ Pressure in Reverse:
Presión dans le lecteur:
Pression dans l'entraînement:

Replacement Parts: (Shift Solenoid, TCM, Internal Harness…ETC.)
Piezas de repuesto:
Pièces de rechange:

Cojinetes principales
Paliers principaux

PTO Description:

No
Non

☐Front Seal ☐ Rear Seal ☐ Oil Pan
Sello delantero
Joint avant

No
Non

☐ No

Sí
Oui

☐ Yes ☐ No

Oil Leak?

Sí
Oui

☐Main Bearings

No
Non

☐ Yes ☐ No

Accessory Drive Modified:

Carcasa del volante
Carter de volant moteur

Cubierta delantra
Couvercle Avant

Engine Only

Sí
Oui

☐ Flywheel housing

Inyectores de combustible
Injecteurs de carburant

Presión en reversa:
Pression en sens inverse:

____