ISUZU KB P190 2007 Workshop Repair Manual

7A4-54 UNIT REPAIR (JR405E)
TRANSMISSION CASE

02CASE-BK06
Legend
1. Transmission case
2. Spring pin (slender)
3. Spring pin (fat)
4. Manual plate
5. Detent spring

6. Parking rod
7. Manual shaft
8. Oil seal
9. Inhibitor switch


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-55
01L&R-CS05
Legend
1. Seal ring
2. Low one-way clutch inner race
3. Return spring
4. Low and reverse brake piston
5. Seal ring
6. Lip seal

7. Transmission case
8. Snap ring
9. Retaining plate
10. Driven plate
11. Drive plate
12. Dish plate



04CASE-AY52

Disassembly steps
1. Harness assembly
Remove the fixing bolt and the harness assembly.


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ISUZU KB P190 2007

7A4-56 UNIT REPAIR (JR405E)

05CASE-AY30

2. Parking rod
• Use a pin punch to force out the parking rod spring pin.


06CASE-AY37

•
Rotate the manual plate as you pull the parking rod free.


08CASE-AY45

3. Detent spring
Remove the fixing bolt and the detent spring.


09CASE-AY28

4. Manual shaft and manual plate
• Remove the manual shaft spring pin.


10CASE-AY21

•
Remove the manual shaft together with the manual
plate.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-57

11CASE-AY01

5. Oil seal
Using a screwdriver, remove the oil seal from the
transmission case.




Inspection
2 – 4 brake drive plates
Measure the 2-4 brake drive plate facing thickness at 3
points and calculate the average value.
If the average value is less than the specified limit, the 2-4
brake drive plate must be replaced.
2 – 4 brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
Low and reverse brake drive plates
Measure the low and reverse brake drive plate facing
thickness at 3 points and calculate the average value.
If the average value is less than the specified limit, the lo
w
and reverse drive plate must be replaced.
Low and reverse brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
2 – 4 brake return springs
• Check the number of effective 2-4 brake return spring
coils.
Effective return spring coils (Standard): 10.2
• Measure the 2-4 brake return spring outside diameter,
free length, and linear diameter.
If any of the measured values exceed the specified limit,
the 2-4 brake return spring must be replaced.
2 – 4 brake return spring measurements (Standard):
Outside diameter = 6.9 mm (0.272 in)
Free length = 22.5 mm (0.886 in)
Linear diameter = 1.1 mm (0.043 in)
Low and reverse brake return springs
• Check the number of effective low and reverse brake
return spring coils.
Effective return spring coils (standard): 4.8
• Measure the low and reverse brake return spring outside
diameter, free length, and linear diameter.
If any of the measured values exceed the specified limit,
the low and reverse return spring must be replaced.
Low and reverse brake return spring measurements
(Standard):
Outside diameter = 11.2 mm (0.441 in)

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ISUZU KB P190 2007

7A4-58 UNIT REPAIR (JR405E)
Free length = 22.3 mm (0.878 in)
Linear diameter = 1.1 mm (0.043 in)


12CASE-AY06

Reassembly steps
1. Oil seal, manual shaft, and manual plate
• Use the oil seal installer to force the manual plate oil
seal into place.
Oil seal installer: 5-8840-2758-0


14CASE-AY21

•
Install the manual shaft together with the manual plate.


15CASE-AY26

•
Drive the spring pin into the transmission case.


16CASE-AY37

2. Parking rod
• Rotate the manual plate while installing the parking rod.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43

•
Use a pin punch to drive the manual plate spring pin into
place.


21CASE-AY48

3. Detent spring
• Install the detent spring and tighten the fixing bolt to the
specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 Ib ⋅
⋅⋅
⋅
in)


23CASE-AY53

4. Harness assembly
• Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.
• Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
Torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 Ib ⋅
⋅⋅
⋅
in)


24ASSY003

5. Low one-way clutch inner race
• Install new seal rings to the low one-way clutch inne
r
race.


25ASSY126

•
Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0039~0.0098 in)


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ISUZU KB P190 2007

7A4-60 UNIT REPAIR (JR405E)

26L&R01

6. Low and reverse brake piston
• Install new seal rings to the low and reverse piston.







RTW 47ASH000701
As shown in a figure, a sealing lip is attached.

27ASSY004

•
Install the low and reverse brake piston to the
transmission case.


28ASSY005

7. Return spring
• Install the return spring to the low and reverse brake
piston.


29ASSY006

8. Low one-way clutch inner race
• Install the low one-way clutch inner race to the
transmission case.
• Temporarily tighten the 7 fixing bolts.


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UNIT REPAIR (JR405E) 7A4-61

31ASSY074

•
Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-wa
y
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 N ⋅
⋅⋅
⋅
m (2.4 kgf ⋅
⋅⋅
⋅
m/17 Ib ⋅
⋅⋅
⋅
ft)


32ASSY007

9. Dish plate, driven plates, drive plates, and retaining
plate (low and reverse brake)
• Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.


33ASSY008



34ASSY009



35N-SPG02

•
Install the N-type spring.


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ISUZU KB P190 2007

7A4-62 UNIT REPAIR (JR405E)





RTW 37AMF0001-X



36ASSY10

•
Install the retaining plate (4).


37ASSY011

•
Install the snap ring.


38L&R03

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil passages of the transmission case to
check low and reverse brake operation.
If the low and reverse brake does not operate, check the
seal rings for damage and replace if necessary. Also
check that no parts have been installed out of place.


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UNIT REPAIR (JR405E) 7A4-63

39L&R04


249L300003

•
Measure the clearance between the low and reverse
retaining plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Low and reverse retaining and snap ring clearance:
0.7~1.1 mm (0.028~0.043 in)
Available low and reverse brake retaining plate
thicknesses
5.2 mm (0.205 in)
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)

10.Dish plate, drive plates, driven plates, and retaining
plate. (2-4 brake)
NOTE:
Ensure the attachment direction of dish plate is correct.
If 2-4 brake clearance measurement is required, it must be
done now.
Brake clearance cannot be measured after the carrier
assembly has been installed.

402-4B08

•
Install the 2-4 brake dish plate to the transmission case
(plate contact surface).


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ISUZU KB P190 2007