ISUZU KB P190 2007 Workshop Repair Manual

7A4–46 UNIT REPAIR (AW30–40LE)
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in) If the thickness is less than the minimum, replace
the disc.
252RY00027
2. Check piston return spring Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
252RY00028
3. Check OD direct clutch piston. Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
252RY00029
4. Check OD direct clutch drum bushings. Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in) If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
252L100009

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UNIT REPAIR (AW30–40LE) 7A4–47
5. Check OD planetary gear bushing.Using a dial indicator, measure the inside diameter
of replace the OD planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.4437 in) If the inside diameter is greater than the maximum,
replace the OD planetary gear.
252RY00031
Reassembly
1. Install the thrust washer to the OD planetary gear, facing the grooved side upward.
252RY00032
2. Install the one-way clutch into the outer race, withthe flanged side of the one-way clutch facing
upward.
252RY00033
3. Install OD one-way clutch with outer race to overdrive planetary gear.
252RY00026

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ISUZU KB P190 2007

7A4–48 UNIT REPAIR (AW30–40LE)
4. Install retaining plate, then install snap ring, using ascrewdriver.
252RY00024
5. Coat the race with petroleum jelly and install it to theplanetary gear.
Race diameter (Reference)
252RY00034
6. Install ring gear flange to OD planetary ring gear.
252RY00023
7. Install snap ring, using a screwdriver.
252RY00022
Inside diameter 24.7 mm (0.972 in)
Outside diameter 41.8 mm (1.646 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–49
8. Install the race and bearing asm onto the ODplanetary ring gear.
Race and bearing asm diameter (Reference)
RTW37ASH001101
9. Coat new O-rings with ATF and install them on the OD direct clutch piston.
10. Being careful not to damage the O-rings, press in the OD direct clutch piston into the clutch drum,
using both hands.
252L100011
11. Install piston return spring.
252L100012
12. Place special tool on the spring retainer, and compress the return spring.
Spring compressor : 5-8840-0195-0
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
252L100007
Inside Outside
Bearing
and race 24.2 mm (0.953 in) 47.8 mm (1.882 in)

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ISUZU KB P190 2007

7A4–50 UNIT REPAIR (AW30–40LE)
13. Install two plates and two discs then install theflange, with the flat side facing downward.
252L100013
14. Install snap ring.
252L100014
15. Check piston stroke of OD direct clutch (C –0)
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
252L100005Using a dial indicator, measure the OD direct clutch
piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
252L100016
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–51
16. Coat the assembled bearing and race withpetroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
252L100015
17. Align the flukes of discs in the direct clutch. Install the OD direct clutch assembly onto the OD
planetary gear.
252L100004
18. Check operation of one-way clutch Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW37ASH004501
En dOFCallout
Inside diameter 28.9 mm (1.138 in)
Outside diameter 50.2 mm (1.976 in)
Legend (1) Free
(2) Lock

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7A4–52 UNIT REPAIR (AW30–40LE)
OD Support Assembly
Disassembled View
RTW77AMF000301
EndOFCallout
Disassembly
1. Check OD brake piston movement.Place the OD support assembly onto the direct
clutch assembly.
252RY00042
Legend
(1) Snap ring
(2) Piston return spring
(3) O-ring (4) OD brake piston
(5) OD support
(6) Oil seal ring

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–53
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
252RY00043
2. Remove the thrust bearing.
3. Remove the race.
4. Remove the thrust washer (plastic).
5. Place special tool on the spring retainer, and compress the return spring with a shop press.
Spring compressor : 5-8840-2170-0 Remove the snap ring with a screwdriver.
252RY00044
6. Romove the piston return spring. 7. Place the OD support onto the direct clutch
assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
252RY00045
8. Remove the O-ring and oil seal rings from OD support.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring Using calipers, measure the free length of the return
spring.
Standard length: 17.2 mm (0.677 in)
252RY00046

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ISUZU KB P190 2007

7A4–54 UNIT REPAIR (AW30–40LE)
Reassembly
1. Coat the two oil seal rings with ATF.Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.
252RY00047
2. Coat two new O-rings with ATF and install them on the OD brake piston.
3. Being careful not to damage the O-rings, press the brake piston into the OD support, using both hands.
252RY00048
4. Install piston return spring.
252RY00049
5. Place special tool on the spring retainer, andcompress the return spring with a shop press.
Spring compressor : 5-8840-2170-0
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
with cutout portion of the OD support.
252RY00050

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UNIT REPAIR (AW30–40LE) 7A4–55
6. Coat the thrust washer (plastic) with petroleum jellyand install it onto the OD suppor t.
NOTE: Make sure that the lug fits into the hole on the
OD support.
252RY00051
7. Coat the race with petroleum jelly, and install it onto the OD support.
Race diameter (Reference)
252RY00052
8. Turn over OD suppor t. Coat the two races with petroleum jelly, and install
them onto the OD support.
Race and bearing diameter (Reference)
252RY00069
9. Check OD brake piston movement. Place the OD support assembly onto the direct
clutch assembly.
252RY00042
Inside diameter 36.7 mm (1.44 in)
Outside diameter 50.85 mm (2.00 in)
Inside Outside
Race (A) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
Bearing and
race (B) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

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ISUZU KB P190 2007