ISUZU KB P190 2007 Workshop Repair Manual

7A4–76 UNIT REPAIR (AW30–40LE)
Second Brake Assembly (B–2)
Disassembled View
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Disassembly
1. Remove second brake assembly from output shaft.
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Legend(1) Second brake assembly
(2) Thrust washer (Plastic)
(3) Snap ring
(4) Spring retainer (5) Piston return spring
(6) Piston sleeve
(7) Second brake piston
(8) O-ring
(9) Second brake drum

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–77
2. Remove the hrust washer (plastic).
3. Place 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 spring retainer and piston return spring.
5. Romove piston sleeve.
6. Holding the second brake piston by hand, apply compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
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7. Remove the o-rings from the second brake piston.
Inspection and Repair
1. Check piston return spring. Using calipers, measure the free length of the return
spring.
Standard length: 18.38 mm (0.724 in)
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Reassembly
1. Coat new O-rings with ATF and install them on the second brake piston.
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2. Being careful not to damage the O-rings, press inthe second brake piston into the second brake
drum.
3. Install piston sleeve.

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ISUZU KB P190 2007

7A4–78 UNIT REPAIR (AW30–40LE)
4. Install piston return spring.
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5. Install spring retainer.
6. Place special tool on the spring retainer, and compress the return spring.
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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7. Check second brake piston movement. Make sure the second brake piston moves smoothly
when applying and releasing the low compressed
air to the second brake drum.
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8. Coat the thrust washer (plastic) with petroleum jelly and install it to the second brake piston, with the
grooved side facing upward.
NOTE: Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–79
9. Install second brake assembly to output shaft.
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ISUZU KB P190 2007

7A4–80 UNIT REPAIR (AW30–40LE)
Rear Planetary Gear Assembly and Output Shaft
Disassembled View
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Legend(1) Snap ring
(2) One-way clutch assembly
(3) Thrust washer
(4) Rear planetary gear
(5) Rear planetary gear assembly
(6) Thrust washer (7) Thrust bearing race
(8) Thrust bearing with race
(9) Rear planetary ring gear
(10) Ring gear flange
(11) Snap ring
(12) Thrust needle roller bearing
(13) Output shaft

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–81
Disassembly
1. Remove second brake assembly from output shaft.
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2. Remove oil seal ring from output shaft.
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3. Remove the seven discs, seven plates and flange(B–3). 4. Remove rear planetary gear from rear planetary ring
gear.
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5. Check operation of No.2 one-way clutch.Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
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Legend
(1) Lock
(2) Free

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ISUZU KB P190 2007

7A4–82 UNIT REPAIR (AW30–40LE)
6. Remove the one-way clutch inner race from the rearplanetary gear.
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7. Remove the snap ring with a screwdriver.
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8. Remove the one-way clutch with retainers from theplanetary gear.
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9. Remove the thrust washer (plastic) from front sideof rear planetary gear.
10. Remove the thrust washer (plastic) from rear side of rear planetary gear.
11. Remove the thrust bearing and race from front side of ring gear flange.
12. Remove the snap ring from rear planetary ring gear.
13. Remove the ring gear flange from rear planetary ring gear.
14. Check disc, plate and flange. Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
 If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.
 Before assembling new discs, soak them in ATF
for at least fifteen minutes.
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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–83
Reassembly
1. Install ring gear flange to the rear planetary ringgear.
2. Install snap ring to the rear planetary ring gear.
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3. Coat the races and bearing with petroleum jelly, and install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)
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4. Coat the thrust washers (plastic) with petroleum jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE: Make sure that the lugs fit into the cutout
portions on the rear planetary gear.
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5. Install the one-way clutch with the flanged side facing upward onto the rear planetary gear.
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6. Install snap ring.
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Inside Outside
Race (A) 28.5 mm (1.122 in) 44.2 mm (1.740 in)
Bearing and
race (B) 27.7 mm (1.091 in) 44.2 mm (1.740 in)

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ISUZU KB P190 2007

7A4–84 UNIT REPAIR (AW30–40LE)
7. While turning counterclockwise, install one-wayclutch inner race to rear planetary gear.
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8. Check operation of one-way clutch.Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
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9. Install rear planetary gear onto rear planetary ring gear.
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10. Install the disc, plate and flange (B –3).
 Install a brake flange onto the rear planetary gear
assembly.
 Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
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Legend
(1) Lock
(2) Free

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–85
Install six clutch discs and six brake plates
alternately, starting with clutch disc, onto the rear
planetary gear assembly.
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11. Coat the oil seal ring with ATF and install it to the output shaft.
NOTE: Do not spread the ring ends too much.
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12. Install output shaft into rear planetary gear assembly.
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13. Install second brake assembly to output shaft.
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ISUZU KB P190 2007