ISUZU KB P190 2007 Workshop Repair Manual

7A4-4 UNIT REPAIR (JR405E)

04CV37

•
Inspect the bottom of the oil pan and strainer netting for
foreign material (clutch facing and metal shavings).
If there is an excessive accumulation of foreign material,
the oil strainer must be replaced.
Further inspection is required to determine the source o
f
the foreign material.



45CV29

5. Control valve assembly
• Disconnect the 2 harness connectors leading to the
control valve.




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UNIT REPAIR (JR405E) 7A4-5

244L300001

•
Remove the 12 bolts and the control valve assembly.

Number of bolts Length
10 (A)
2 (B) 40 mm (1.57 in)
30 mm (1.18 in)



42ASSY118

NOTE:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the valve
from turning).


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ISUZU KB P190 2007

7A4-6 UNIT REPAIR (JR405E)

10ASSY116

6. Converter housing
• Position the automatic transmission so that the
converter housing is facing up.
• Remove the 8 bolts and the converter housing.



11ASSY068

7. O-ring
Remove the O-ring from the input shaft.


12ASSY067

8. Oil pump assembly and bearing race
• Remove the 8 bolts.
• Use a slide hammer to remove the oil pump assembl
y
from the transmission case.
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.
• Remove the bearing race from the oil pump assembly.
• Inspect the bearing race surfaces for damage.


14ASSY057

9. Input shaft
Pull the input shaft free.


15ASSY049

10.Clutch pack (Reverse and high clutch assembly) and
bearing
• Pull the clutch pack free.
• Remove the bearing from the clutch pack.



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UNIT REPAIR (JR405E) 7A4-7

16ASSY047

11.High clutch hub, bearing, and bearing race
• Remove the clutch hub, bearing (with bearing race), and
the bearing race.
• Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.
• Inspect the bearing race surfaces for damage.



17ASSY040

12.Front sun gear, bearing, and bearing race
• Remove the bearing, the front sun gear, and the bearing
race.
• Remove the bearing and the bearing race from the front
sun gear.
• Inspect the bearing race surfaces for damage.


19ASSY113

13.2-4 brake retainer
• Remove the brake seal ring and the sleeve.



23ASSY030

•
Attach the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0



24ASSY029

•
Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.
• Remove the spring compressor.



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7A4-8 UNIT REPAIR (JR405E)

25ASSY019

•
Remove the 2-4 brake retainer and return spring.



26ASSY026

14.Carrier assembly (Carrier and low clutch assembly),
bearing, bearing race, and 2 – 4 brake assembly
• Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.
• Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.



27U-SPG02

•
Remove the 3 brake springs from the transmission case.



28L&R06

15.Low and reverse brake
• Remove the snap ring.
• Pull the low and reverse brake free.


16.Rear extension (2WD) or Adapter case (4WD)
• Rotate the transmission case so that the oil pan opening
is facing up.
• Remove the 10 bolts and the rear extension (2W D) o
r
the adapter case (4W D).


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UNIT REPAIR (JR405E) 7A4-9

29ASSY091

17.Output shaft
• Pull the output shaft from the transmission case.


30ASSY089

•
Remove the bearing (with bearing race) from the
transmission case.


31ASSY124

18.Parking pawl, shaft, spring, and spacer
Remove the parking pawl, shaft, spring and spacer from the
transmission case.


36ASSY075

19.Actuator support
Remove the actuator support from the transmission case.


37ASSY074

20.Low one-way clutch inner race and bearing
• Loosen the 7 bolts securing the low one-way clutch inne
r
race.
NOTE:
Loosen the bolts a little at a time as uniformly as possible
to prevent the inner race from tilting and becoming
jammed.
• Remove the 6 bolts. Support the low one-way clutch
inner race with your hand and remove the final bolt.

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7A4-10 UNIT REPAIR (JR405E)

39ASSY006

•
Remove the bearing and the low one-way clutch inner
race from the transmission case.
• Remove the bearing from the low one-way clutch inne
r
race.


40ASSY005

21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.


41L&R02

22.Low and reverse brake piston
• Force compressed air (390 kPa/4.0 kgf/cm
2/57 psi)
through the transmission case oil passages.


42ASSY004

•
Remove the low and reverse brake piston from the
transmission case.


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UNIT REPAIR (JR405E) 7A4-11
CONTROL VALVE ASSEMBLY


01CV40

Disassembly steps
1. Oil strainer
Remove the 13 bolts and the oil strainer from the control
valve assembly.


02CV26

2. Harness assembly
Remove the harness assembly.


04CV21

3. Solenoid fixing plate
4. Harness bracket • Remove the 11 bolts and the solenoid fixing plate
together with the harness bracket.


05CV20



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7A4-12 UNIT REPAIR (JR405E)

06CV19

5. Solenoid
6. Oil pressure switch Remove the 6 solenoids together and the 3 oil pressure
switches.


07CV17

7. Control valve upper body
8. Control valve lower body
9. Separation plate • Remove the 17 bolts securing the control valve uppe
r
body, the control valve lower body, and the separation
plate.


08CV16

•
Separate the upper body, the lower body, and the
separation plate.
NOTE:
Take care not to drop or lose the parts at the inside of the
control valve.

Inspection
•
Inspect the separation plate for wear and other damage.


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UNIT REPAIR (JR405E) 7A4-13
Reassembly steps
Coat the parts with ATF before installing them.

11CV18

1. Control valve upper body
2. Control valve lower body
3. Separation plate Assemble the control valve upper body, the lower body, and
the separation plate.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)


244L300002





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ISUZU KB P190 2007