ISUZU KB P190 2007 Workshop Repair Manual

7A4-74 UNIT REPAIR (JR405E)

192-4B22

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the transmission case oil passage to 2-4 brake
operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing
• Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040
• Install the front sun gear to the transmission case.


22ASSY042
• Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-75

24ASSY047

•
Install the high clutch hub and the bearing race to the
transmission case.


25R&H42

11.Clutch pack (reverse and high clutch assembly)
• Install the bearing (with bearing race) to the clutch pack.
NOTE:
•
••
•
The black side (bearing race) of the bearing must
contact the clutch pack.
•
••
•
Apply Vaseline to the bearing.


26ASSY049

•
Install the clutch pack and bearing to the transmission
case.



27ASSY051

•
Install the bearing to the clutch pack.
NOTE:
Apply Vaseline to the bearing.







RTW 47ASH000101

Total end play measurement
• Install the bearing race (oil pump) to the clutch pack.
• Measure the distance (A) between the oil pump
installation surface and the bearing race.


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ISUZU KB P190 2007

7A4-76 UNIT REPAIR (JR405E)





RTW 47ASH000201

•
Measure the distance (B) between the bearing race
installation surface and the machined surface.
• Calculate the total end play using the following formula.
Total end play = distance (A) – distance (B)
If the measured and calculated end play is outside the
specified range, replace the existing bearing race with a
bearing race of the proper size (thickness).
Total end play = 0.25~0.55 mm (0.0098~0.0217 in)
Available oil pump bearing race thicknesses
1.4 mm (0.055 in)
1.6 mm (0.063 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)
2.2 mm (0.087 in)
2.4 mm (0.094 in)





RTW 47ASH000201


28ASSY058

12.Input shaft
Install the input shaft.


29PUMP02

13.Oil pump assembly
• Install a new O-ring to the outside of the oil pump.
• Install the bearing race to the oil pump.
NOTE:
Apply Vaseline to the bearing race.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-77

30ASSY067

•
Apply ATF to the O-ring at the outside of the oil pump.
• Install the oil pump assembly to the transmission case.
•
Apply sealing agent (TB1215) to the threaded surfaces
of the 8 fixing bolts and tighten to the specified torque.
Torque: 58 N ⋅
⋅⋅
⋅
m (5.9 kgf ⋅
⋅⋅
⋅
m/43 Ib ⋅
⋅⋅
⋅
ft)


31ASSY068

14.O-ring
Install a new O-ring to the input shaft.


32ASSY116

15.Converter housing
Install the converter housing and tighten the bolts to the
specified torque. Torque: 53 N ⋅
⋅⋅
⋅
m (5.4 kgf ⋅
⋅⋅
⋅
m/39 Ib ⋅
⋅⋅
⋅
ft)


33ASSY075

16.Actuator support
Install the actuator support.


34ASSY077

17.Parking pawl, shaft, spring, and spacer
Install the parking pawl, the shaft, the spring, and the
spacer.


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7A4-78 UNIT REPAIR (JR405E)

35ASSY082


36ASSY084


37ASSY086


38OUTPUT25



29ASSY089
18.Output shaft
• Install a new seal ring to the output shaft assembly.
• Measure the gap between the seal ring and the ring
groove.
If the gap is outside the specified range, the output shaft
must be replaced.
Seal ring and ring groove gap:
0.10~0.25 mm (0.0039~0.0098 in)
• Install the bearing to the case.
NOTE:
•
••
•
Apply Vaseline to the bearing (with bearing race).
•
••
•
The black side (bearing race) of the bearing must be
visible.

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UNIT REPAIR (JR405E) 7A4-79

40ASSY091

•
Push the output shaft into place.


19.Rear extension (2WD) or adapter case (4WD)
• Use the oil seal installer to install the oil seal to the rea
r
extension (2W D) or adapter case (4W D).
Oil seal installer:
5-8840-2769-0 (2WD)
5-8840-2770-0 (4WD)

41ASSY096

•
Install the bearing (with bearing race) to the rear
extension (2W D) or adapter case (4W D).
NOTE:
•
••
•
The black side (bearing race) of the bearing must be
visible.
•
••
•
Apply Vaseline to the bearing.




249L300005

•
Apply sealing agent (TB1216B) to the rear extension
(2W D) or adapter case (4W D) contact surfaces.



249L300006
• Install the rear extension (2W D) or adapter case (4W D)
to the transmission case and tighten the 10 bolts to the
specified torque.
Torque: 53 N ⋅
⋅⋅
⋅
m (5.4 kgf ⋅
⋅⋅
⋅
m/39 Ib ⋅
⋅⋅
⋅
ft)


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7A4-80 UNIT REPAIR (JR405E)

43ASSY119

20.Control valve assembly
•
Align the manual valve and the manual plate of the
transmission case.










• Install the control valve assembly and tighten the 12
fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

44ASSY121


Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)



45CV29

•
Connect the harness assembly and control valve
assembly connectors.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-81
244L300001


21.Oil pan
• Install a new gasket and the oil pan.
• Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
in)

47INH-SW 01

22.Inhibitor switch
• Secure the inhibitor switch (1) by hand-tightening the 2
bolts.
• Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
• Tighten the 2 inhibitor switch bolts to the specified
torque.

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7A4-82 UNIT REPAIR (JR405E)
Torque: 6 N⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 lb ⋅
⋅⋅
⋅
in)
• Remove the holding fixture from the transmission case.



RTW 47ASH001001

23.Speed sensor and turbine sensor
• Apply ATF to the new O-rings and install them in the
speed sensor (2) and the turbine sensor (3).
• Install the speed sensor and the turbine sensor. Tighten
the bolt to the specified torque.
Torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 Ib ⋅
⋅⋅
⋅
in)
24.Torque converter • Pour the new ATF into the torque converter.
• Shake the torque converter to thoroughly clean the
inside.
• Drain the ATF from the torque converter.
• Pour the new ATF into the torque converter.
NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.


RTW 47ASH000901

•
Install the torque converter.
• Measure the torque converter end play (A).
If the measured value is greater than the specified
minimum, the torque converter is correctly installed.
Torque converter end pay (Minimum): 67 mm (2.64
in)


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UNIT REPAIR (JR405E) 7A4-83
SERVICE STANDARD
Name BESCO ATF III ATF
Quantity L (US gal/Imp gal) 9.2 – 9.6 (2.43-2.54/2.02-2.11)
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plates / driven plates 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coils 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring Linear diameter mm (in) 1.2 (0.047)
Number of drive plates / driven plates 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coils 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring Linear diameter mm (in) 1.1 (0.043)
Number of drive plates / driven plates 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.024 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in) 5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plates / driven plates
6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)

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ISUZU KB P190 2007