ISUZU KB P190 2007 Workshop Repair Manual

7A4-24 UNIT REPAIR (JR405E)
Disassembly steps
• Remove the oil filter from the control valve lower body.

244L300009
Legend
1. Oil filter
2. Separation plate



•
Remove the control valve from the control valve lower
body.
NOTE:
Place the control valve where it will not get mixed up with
the other parts.

Inspection
Valve
Inspect each of the valves for denting and other damage.
Spring
Inspect each of the springs for wear and fatigue.

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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-25
Valve specifications
244L300008



















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7A4-26 UNIT REPAIR (JR405E)
No. Valve
nomenclature Diameter
(mm / in) Length
(mm / in) Configuration
14 Pressure relief ---- ----

15 Pressure
regulator 16.0 /
0.630 89.5 /
3.524
16 Low and reverse
brake fail (A) 10.0 /
0.394 52.0 /
2.047
17 Fail 12.0 /
0.472 53.5 /
2.106
18 Low and reverse
brake amp 12.0 /
0.472 55.5 /
2.185
19 2 – 4 brake fail
(A) 10.0 /
0.394 65.5 /
2.579
20 Low clutch amp
(B) 12.0 /
0.472 53.0 /
2.087
21 Torque
converter relief 10.0 /
0.394 37.4 /
1.472
22 2 – 4 brake
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
23 High clutch
accumulator 10.0 /
0.394 31.0 /
1.220














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UNIT REPAIR (JR405E) 7A4-27

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter
(mm / in) Linear
diameter
(mm / in) Number of
coils
14 Pressure relief 49.0 / 1.929 7.6 / 0.299 1.1 / 0.043 17.3
15 Pressure regulator 30.5 / 1.201 14.0 / 0.551 1.4 / 0.055 5.7
16 Low and reverse brake fail (A) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
17 Fail 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
18 Low and reverse brake amp 19.5 / 0.768 7.9 / 0.311 0.5 / 0.020 6.9
19 2 – 4 brake fail (A) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
20 Low clutch amp (B) 26.0 / 1.024 11.0 / 0.433 0.5 / 0.020 6.9
21
Torque converter relief More than 47.2
/ 1.858 9.2 / 0.362 1.6 / 0.063 20.2
22 2 – 4 brake solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
23 High clutch accumulator
51.0 / 2.008 6.5 / 0.256 0.8 / 0.031 23.5

Oil pressure switch
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to the oil
pressure switch to check the oil pressure switch continuity
between the connector and screw.






244L300011

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between harness
terminals 7 and 6 (ground).

Oil temperature sensor resistance: 2,400 ～
～～
～
2,600 ohms
(20 °
°°
°
C)


Solenoids
Measure the resistance of each solenoid.

Resistance:
Brown connector – 3.0 ∼
∼∼
∼
3.4 ohms (20 °
°°
°
C)
Gray connector – 12.0 ∼
∼∼
∼
13.2 ohms (20 °
°°
°
C)
White connector – 12.2 ∼
∼∼
∼
13.4 ohms (20 °
°°
°
C)

Reassembly steps
• Coat the parts with ATF before installing them.
• Install the control valve to the control valve lower body.
• Install the oil filter to the control valve lower body.



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ISUZU KB P190 2007

7A4-28 UNIT REPAIR (JR405E)
OIL PUMP ASSEMBLY

01PUMP32
Legend
1. Oil seal
2. O-ring (small)
3. Oil pump housing
4. Inner rotor
5. Outer rotor

6. Oil pump cover
7. O-ring (large)
8. Seal ring (large)
9. Seal ring (small)
10. Bearing race


02PUMP07


Disassembly steps
1. Oil pump cover
2. Oil pump housing • Loosen the 8 bolts evenly a little at a time.


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UNIT REPAIR (JR405E) 7A4-29

04PUMP10

•
Separate the oil pump cover from the oil pump housing
by tapping on each of the bolts with a plastic hammer.



06PUMP13

3. Inner rotor
Remove the inner rotor from the oil pump housing.



07PUMP14

4. Outer rotor
Remove the outer rotor from the oil pump housing.



15PUMP18

5. O-ring (small)
Remove the O-ring (small) from the oil pump housing.



08PUMP09

6. O-ring (large)
Remove the O-ring (large) from the oil pump cover.



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7A4-30 UNIT REPAIR (JR405E)

09PUMP05

7. Seal ring
Remove the 4 seal rings from the oil pump cover.



11PUMP43

Inspection
Oil pump cover
• Install new seal rings to the oil pump cover.
NOTE:
The seal ring with the large inside diameter fits into the
primary mating surface of the cover.
• Measure the gap between the seal ring and the seal ring
groove.
If the measured gap is outside the specified range, the
oil pump cover must be replaced.
Seal ring and seal ring groove gap: 0.10 ∼
∼∼
∼
0.25 mm
(0.0039 ∼
∼∼
∼
0.0098 in)

12PUMP45

Inner rotor
• Install the inner rotor to the oil pump housing.
• Use a straight edge to measure the side clearance
between the oil pump housing and the inner rotor.
If the measured clearance is outside the specified range,
the inner rotor must be replaced.
Oil pump housing and inner rotor side clearance:
0.02~0.04 mm (0.0008~0.0016 in)

13PUMP46

Outer rotor
• Install the outer rotor to the oil pump housing.
• Measure the gap between the outer rotor and the
crescent.
If the measured gap is outside the specified range, the
outer rotor must be replaced.
Outer rotor and crescent gap:
0.02~0.15 mm (0.0008~0.0059 in)

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UNIT REPAIR (JR405E) 7A4-31


Reassembly steps

15PUMP18

1. O-ring (small)
Install new O-ring (small) to the oil pump housing.

16PUMP29

2. Outer rotor
3. Inner rotor Install the outer rotor and the inner rotor to the oil pump
housing.

17PUMP42

NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.

18PUMP07

4. Oil pump cover
5. Oil pump housing Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
Torque: 9 N ⋅
⋅⋅
⋅
m (0.9 kgf ⋅
⋅⋅
⋅
m/78 Ib ⋅
⋅⋅
⋅
in)



6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring Install the 4 seal rings to the oil pump cover.

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ISUZU KB P190 2007

7A4-32 UNIT REPAIR (JR405E)
CLUTCH PACK (REVERSE AND
HIGH CLUTCH ASSEMBLY)

01R&H17
Legend
1. Reverse and high clutch drum
2. Seal ring (reverse clutch)
3. Lip seal (reverse clutch)
4. Reverse clutch piston
5. Seal ring (small, high clutch)
6. Seal ring (large, high clutch)
7. High clutch piston
8. Return spring
9. High clutch cover
10. Snap ring

11. Dish plate (high clutch)
12. Driven plate (5, high clutch)
13. Drive plate (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plate (2, reverse clutch)
18. Drive plate (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)


02R&H18

Disassembly steps
1. Snap ring
Remove the reverse clutch snap ring.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-33

03R&H21

2. Retaining plate, drive plates, driven plates and dish
plate
Remove the reverse clutch retaining plate, the 2 drive
plates, the 2 driven plates, and the dish plate.


04R&H22

3. Snap ring
Remove the high clutch snap ring.


05R&H25

4. Retaining plate, drive plates, driven plates and dish
plate
Remove the high clutch retaining plate, the 5 drive plates,
the 5 driven plates, and the dish plate.


07R&H28

5. Snap ring
6. High clutch cover
7. Return spring • Install the spring compressor to the reverse and high
clutch drum.
Spring compressor: 5-8840-2767-0
• Carefully press the high clutch cover down.
Take care not to damage the return spring.
• Remove the snap ring.
• Remove the high clutch cover and the return spring.





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ISUZU KB P190 2007