ISUZU KB P190 2007 Workshop Repair Manual

7A4–86 UNIT REPAIR (AW30–40LE)
First and Reverse Brake (B–3)
Disassembled View
246RY00024-X
EndOFCallout
Legend(1) Thrust bearing and race
(2) Snap ring
(3) Piston return spring
(4) First and reverse brake piston No.2
(5) O-ring (6) Reaction sleeve
(7) O-ring
(8) First and reverse brake piston No.1
(9) O-ring
(10) Rear planetary gear assembly and output shaft

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–87
Disassembly
1. Remove assembled thrust bearing and race fromtransmission case.
247RY00043
2. Check first and reverse brake piston movement.Make sure that first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
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3. Set special tool on the spring retainer, and compress the return spring.
Spring compressor: 5-8840-0254-0
Remove the snap ring with snap ring pliers.
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4. Remove the piston return spring.
5. Remove the first and reverse brake piston No.2. Holding the first and reverse brake piston No.2 by
hand, apply compressed air to the transmission
case to remove the first and reverse brake piston
No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air,
lift the piston out with needle-nose pliers.
246RY00016

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ISUZU KB P190 2007

7A4–88 UNIT REPAIR (AW30–40LE)
6. Remove the O-ring from first and reverse brakepiston No.2.
7. Remove the reaction sleeve. Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: 5-8840-2173-0
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8. Remove the O-ring from reaction sleeve.
9. Remove the first and reverse brake piston No.1. Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the
transmission case.
Piston puller: 5-8840-2174-0
247RY00044
10. Remove the O-rings from first and reverse brake pistion No.1.
Reassembly
1. Coat three new O-rings with ATF.Install the two O-rings on the No.1 piston.
2. Install the O-ring on the reaction sleeve.
3. Install the first and reverse brake piston No.1 to the reaction sleeve.
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4. Coat a new O-ring with ATF and install it on the firstand reverse brake piston No.2.
5. Install the first and reverse brake piston No.1 with reaction sleeve onto the first and reverse brake
piston No.2.
246RY00019

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–89
6. Align the teeth of the first and reverse brake pistonNo.2 into the proper grooves.
Being careful not to damage the O-rings, press in
the first and reverse brake piston No.2 with No.1
into the transmission case.
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7. Place piston return spring onto first and reverse brake piston No.2.
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8. Set special tool as shown, and compress the returnspring with special tool.
Spring compressor: 5-8840-0254-0
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.
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9. Check first and reverse brake piston movement. Make sure the first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
246RY00022

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ISUZU KB P190 2007

7A4–90 UNIT REPAIR (AW30–40LE)
10. Coat the assembled bearing and race withpetroleum jelly.
Install the assembled bearing and race facing the
bearing side upward.
Bearing and race diameter (Reference)
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Inside diameter 39.38 mm (1.550 in)
Outside diameter 58.15 mm (2.289 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–91
Transmission Case
Disassembled View
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EndOFCallout
Disassembly
1. Using a chisel, cut off the spacer and remove it fromthe shaft.
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Legend
(1) Spacer
(2) Pin
(3) Manual valve lever shaft (4) Manual valve lever
(5) Oil seal
(6) Oil seal

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ISUZU KB P190 2007

7A4–92 UNIT REPAIR (AW30–40LE)
2. Using a punch, drive out the pin.
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3. Pull the manual valve lever shaft out through thecase by the threads.
4. Take out the manual valve lever.
5. Using a screwdriver, remove the oil seals.
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Reassembly
1. Coat a new oil seal lip with multi purpose grease. Using special tool, drive in the oil seal.
Oil seal installer : 5-8840-2169-0
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2. Assemble a new spacer to the manual valve lever.
3. Install the manual valve lever shaft to the transmission case through the manual valve lever by
the threads.
249RY00005

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–93
4. Drive in the pin with the slot at a right angle to theshaft.
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5. Match the spacer hole to the lever staking hollowand stake the spacer to the lever.
Make sure the manual valve lever shaft turns
smoothly.
249RY00003

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ISUZU KB P190 2007

7A4–94 UNIT REPAIR (AW30–40LE)
Torque Converter
Inspection and Repair
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : 5-8840-2168-0
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.
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1. One-way clutch test. The clutch should lock when turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5 N ·m (0.25kgf ·m/22 Ib ·in) of
torque should be required to rotate the clutch
clockwise. If necessary, clean the converter and
retest the clutch. Replace the conver ter if the clutch
still fails the test.

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–95
Adapter Housing (4 × 4)
Disassembled View
241R200005
EndOFCallout
Disassembly
1. Using a screwdriver, remove the oil seal.
Reassembly
1. Using oil seal installer, install the new oil seal to the
adapter housing.
Oil seal installer : 5-8840-2282-0
240RY00003
Legend
(1) Oil seal
(2) Adapter housing

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ISUZU KB P190 2007