ISUZU KB P190 2007 Workshop Repair Manual

7A4–26 UNIT REPAIR (AW30–40LE)
8. Install the snap ring.
248RY00014
9. While turning the sun gear input drum clockwise,install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.
248RY00020
10. Install the front planetary gear and bearing to the sun gear.
NOTE: Confirm the bearing and race is installed
correctly. Bearing and race diameter (Reference)
247RY00012With wooden blocks under the output shaft, stand
the transmission on the output shaft.
247RY00013
Inside Outside
Bearing 35.6 mm (1.40 in) 47.7 mm (1.88 in) Race 33.7 mm (1.33 in) 47.6 mm (1.87 in)

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UNIT REPAIR (AW30–40LE) 7A4–27
11. Using snap ring pliers, install the snap ring.
248RY00011
12. Coat the bearing race with petroleum jelly and installit onto the front planetary gear.
Bearing race diameter (Reference)
247RY00014
13. Insert the second coast brake band to the transmission case.
248RY00010
14. Install the E-ring and pin.
Install the pin through the brake band.
248RY00021
Bearing race Diameter
Inside 34.3 mm (1.350 in)
Outside 47.8 mm (1.882 in)

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ISUZU KB P190 2007

7A4–28 UNIT REPAIR (AW30–40LE)
Install the E-ring to the pin.
248RY00022
15. Coat the bearing and race with petroleum jelly and
install them onto the forward clutch.
Bearing and race diameter (Reference)
248RY00023
16. Coat the race with petroleum jelly and install it onto the front planetary ring gear.
Race diameter (Reference)
247RY00015Align the flukes of the discs in the forward clutch.
247RY00016
Inside Outside
Bearing 26.0 mm (1.024 in) 46.7 mm (1.839 in) Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)
Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–29
17. Align the spline of the front planetary gear with theflukes of the discs and install the front planetary
gear to the forward clutch.
247RY00017
18. Coat the bearing and race with petroleum jelly and install them onto the ring gear.
Bearing and race diameter (Reference)
247RY00019
19. Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission
case.
247RY00018
 Using vernier calipers, measure the distance
between the sun gear input drum and direct
clutch drum as shown in the figure.
Height: 2.5 – 4.5 mm (0.098 – 0.177 in)
If the values are nonstandard, check for an
improper installation.
248RY00024
Inside Outside
Bearing 35.15 mm (1.384 in) 53.65 mm (2.112 in) Race 35.15 mm (1.384 in) 53.65 mm (2.112 in)

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ISUZU KB P190 2007

7A4–30 UNIT REPAIR (AW30–40LE)
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
Assembled bearing and race diameter
(Reference)
248RY00025
20. Assembly second coast brake piston assembly. Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
RUW37ASH004401
E ndOFCallout
21. Coat two new oil seals with ATF and install them to the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
248RY00027
22. Check piston stroke of second coast brake Place a mark on the second coast brake piston rod
as shown in the figure.
248RY00005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
Inside
Outside
Bearing
and race 33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend (1) Second coast brake piston
(2) Oil seal
(3) Piston rod

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–31
If the values are nonstandard, check for an improper
installation.
248RY00004
23. Coat the race with petroleum jelly and install it onto the overdrive support assembly.
Race diameter (Reference)
252RY00007
24. Aim the bolt and oil holes of the overdrive suppor t toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.
252RY00005
25. Using snap ring pliers, install the snap ring as shown in the figure.
252RY00008
Inside Outside
Race 36.7 mm (1.44 in) 50.8 mm (2.00 in)

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ISUZU KB P190 2007

7A4–32 UNIT REPAIR (AW30–40LE)
Install and tighten the two bolts.
Torque: 25 N ·m (2.5 kgf ·m / 18 lb ·ft)
252RY00004
26. Check end of output shaft.
Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)
247RY00020
27. Install the (flat ring) 4.0 mm (0.157 in) thick flange
with the rounded edge side of the flange facing the
disc.
Alternately install four discs and four plates. (Disc
first)
252RY00009
28. Install the (stepped ring) flange with the flat side of the flange facing the disc.
Install the snap ring.
Snap ring (Reference)
246RY00001
Inside diameter 167.9 mm (6.61 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–33
29. Check piston stroke of overdrive brake.Place a dial indicator onto the overdrive brake
piston as shown in the figure.
252RY00003Measure the stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure.
Piston stroke: 1.75 – 2.05 mm (0.0689 – 0.0807 in)
If the values are nonstandard, check for an improper
installation.
Available flange size
244RY00001
Remove the snap ring.
246RY00001Remove one flange, four plates and four discs.
246RY00026
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

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ISUZU KB P190 2007

7A4–34 UNIT REPAIR (AW30–40LE)
30. Coat the bearing and races with petroleum jelly andinstall them onto the overdrive support.
Bearing and races diameter (Reference)
252RY00010
31. Install the overdrive planetary ring gear.
252RY00002
32. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
Bearing and race diameter (Reference)
252RY00011Install the (flat ring) 4.0 mm (0.157 in) thick flange
with the rounded edge side of the flange facing the
disc.
Alternately install four discs and three plates. (Disc
first)
Install the (stepped ring) flange with the flat side of
the flange facing the disc.
Install the snap ring.
33. Coat the race with petroleum jelly and install it onto the planetary gear.
Race diameter (Reference)
252RY00001
Inside Outside
Race
(Front) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
Bearing
and race (Rear) 33.7 mm (1.327 in) 50.1 mm (1.972 in)Inside
Outside
Bearing
and race 24.2 mm (0.953 in) 47.8 mm (1.882 in)
Inside Outside
Race 24.7 mm (0.972 in) 41.8 mm (1.646 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–35
34. Install the overdrive planetary gear and direct clutch.
252L100001
35. Coat the assembled bearing and race withpetroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
252L100018
36. Coat the race with petroleum jelly and install it onto the oil pump.
Race diameter (Reference)
252RY00014
37. Coat the O-ring with ATF and install it around the pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CAUTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N ·m (2.2 kgf ·m/16 lb ·ft)
38. Check input shaft rotation. Make sure the input shaft rotates smoothly.
241RY00003
Inside Outside
Bearing
and race 28.9 mm (1.138 in) 50.2 mm (1.976 in)
Inside
Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

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ISUZU KB P190 2007