ISUZU KB P190 2007 Workshop Repair Manual

7A4–36 UNIT REPAIR (AW30–40LE)
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the next
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged inproper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in place.

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–37
Oil Pump
Disassembly View
RTW77AMF000201
EndOFCallout
Disassembly
1. Use torque converter as work stand.Remove 2 oil seal rings from stator shaft.
241RY00005
Legend
(1) Oil pump body
(2) Oil pump drive gear
(3) Oil pump driven gear (4) Stator shaft
(5) O-ring
(6) Oil seal ring

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ISUZU KB P190 2007

7A4–38 UNIT REPAIR (AW30–40LE)
2. Remove the O-ring.
3. Remove the stator shaft.
4. Remove the oil pump drive gear.
5. Remove the oil pump driven gear.
6. Remove the oil pump body. Remove 13 bolts, and then remove the stator shaft
from oil pump body.
Then remove drive and driven gear.
241RY00006
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check oil pump body bushing. Using a dial indicator, measure the inside diameter
of the oil pump body bushing.
Maximum inside diameter: 38.19 mm (1.5035 in) If the inside diameter is greater than the maximum,
replace the oil pump body.
241RY00007
2. Check stator shaft bushing. Using a dial indicator, measure the inside diameter
of the stator shaft bushing.
Maximum inside diameter: Front side: 21.58 mm
(0.8496 in)
Maximum inside diameter: Rear side: 27.08 mm
(1.0661 in)
If the inside diameter is greater than the maximum,
replace the stator shaft.
241RY00008
3. Check tip clearance of both gears. Measure between the gear teeth and the
cresent-shaped part of the pump body.
Standard tip clearance: 0.11 – 0.14 mm (0.0043 –
0.0055 in)
Maximum tip clearance: 0.19 mm (0.0075 in) If the tip clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
241RY00009

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UNIT REPAIR (AW30–40LE) 7A4–39
4. Check body clearance of driven gear.Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
Standard body clearance: 0.07 – 0.15 mm (0.0028
– 0.0059 in)
Maximum body clearance: 0.2 mm (0.0079 in) If the body clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
241RY00010
5. Check side clearance of both gears. Using a steel straightedge and a feeler gauge,
measure the side clearance of both gears.
Standard side clearance: 0.02 – 0.05 mm (0.0008 –
0.0020 in)
Maximum side clearance: 0.1 mm (0.004 in) If the side clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
241RY00011
6. Check oil seal. Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
241RY00012Using special tool, install a new oil seal.
The oil seal end should be flush with the outer edge
of the pump body.
Oil seal installer : 5-8840-2256-0
Coat the oil seal lip with multipurpose grease.
241RY00013

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7A4–40 UNIT REPAIR (AW30–40LE)
Reassembly
1. Place the oil pump body on the torque converter.
2. Coat the driven gear and drive gear with ATF.
3. Install the driven gear and drive gear.
241RY00014
4. Align the stator shaft with the bolt holes. Tighten the thirteen bolts.
Torque: 10 N ·m (1.0 kg ·m/87 Ib ·in)
241RY00006
5. Install the oil seal ring.
 Coat the oil seal rings with ATF.
 Contract the oil seal rings as shown, and install
them onto the stator shaft.
NOTE: Do not spread the ring ends too much.
241RY00015
6. Coat a new O-ring with ATF and install it to the oil pump body.
O-ring size (Reference)
241RY00016
Inside diameter 204.9 mm (8.067 in)
Thickness 3.5 mm (0.138 in)

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UNIT REPAIR (AW30–40LE) 7A4–41
7. Check oil pump drive gear rotation.Make sure the drive gear rotates smoothly when
installed to the torque converter.
241RY00017

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7A4–42 UNIT REPAIR (AW30–40LE)
OD Planetary Gear and OD Direct Clutch Assembly (C–0)
Disassembled View
RTW77ALF000901
EndOFCallout
Legend(1) Thrust bearing
(2) OD direct clutch assembly
(3) O-ring
(4) OD direct clutch piston
(5) O-ring
(6) Piston return spring
(7) Snap ring
(8) Clutch disc
(9) Flange
(10) Snap ring (11) Thrust bearing
(12) Snap ring
(13) Ring gear flange
(14) OD planetary ring gear
(15) Thrust bearing
(16) Race
(17) OD planetary gear assembly
(18) Thrust washer
(19) OD one-way clutch
(20) Retaining plate
(21) Snap ring

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UNIT REPAIR (AW30–40LE) 7A4–43
Disassembly
1. 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
2. Remove OD direct clutch assembly from OD planetary gear assembly.
252L100004
3. Then remove thrust bearing with the race from ODdirect clutch drum. 4. 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.
252L100005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
252L100016

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7A4–44 UNIT REPAIR (AW30–40LE)
5. Remove snap ring from clutch drum.
252L100006
6. Remove flange, two discs and two plates.
7. Place special tool on the spring retainer and compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : 5-8840-0195-0
252L100007
8. Remove piston return spring
9. Remove the OD direct clutch piston with O-ring.
 Place the oil pump onto the torque converter and
then place the OD direct clutch onto the oil pump.
 Holding the OD direct clutch piston by hand,
apply compressed air to the oil pump to remove
the OD direct clutch piston. 
Remove the OD direct clutch piston.
252L100008
10. Remove two O –rings from piston.
11. Remove bearing and race from OD planetary ring gear.
RTW46BSH000301

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UNIT REPAIR (AW30–40LE) 7A4–45
12. Remove snap ring.
252RY00022
13. Remove ring gear flange from OD planetary ringgear.
252RY00023
14. Remove the Race. 15. Remove snap ring, using screwdriver.
252RY00024
16. Remove retaining plate from OD planetary gear.
252RY00025
17. Remove OD one-way clutch with outer race.
252RY00026

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ISUZU KB P190 2007