ISUZU KB P190 2007 Workshop Repair Manual

7A4-34 UNIT REPAIR (JR405E)

08R&H36

8. High clutch piston
9. Reverse clutch piston • Install the reverse and high clutch drum to the oil pump.
• Force compressed air into the oil pump oil channels.
• Remove the high clutch piston and the reverse clutch
piston.


09R&H37



12R&H39

10.Seal ring (high clutch)
Remove the 2 seal rings from the high clutch piston.

13R&H38

11.Seal ring (reverse clutch)
Remove the 2 seal rings from the reverse clutch piston.




Inspection
Drive plates
• Measure the drive plate facing thickness at 3 points.
• Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-35
Return springs • Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2
• Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)


10R&H40

Reverse clutch piston
• Apply compressed air (390 kPa/4.0 kgf/cm
2/57 psi) to
the reverse clutch piston from the outside to the inside.
The flow of air should be blocked.


11R&H44

•
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.


12R&H39

Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.


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ISUZU KB P190 2007

7A4-36 UNIT REPAIR (JR405E)

13R&H38

2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.




RTW 47ASH000601
As shown in a figure, oil seal lip is attached.

14R&H32

3. Reverse clutch piston
Install the reverse clutch piston to the reverse and high
clutch drum.


15R&H31

4. High clutch piston
Install the high clutch piston to the reverse clutch piston.


16R&H33

5. Return spring
Install the return spring to the high clutch piston.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-37

17R&H30

6. High clutch cover
• Carefully center the high clutch cover and install it.
NOTE:
If the clutch cover is not centered, the cover outside seal
gum will be forced into the piston area where it will be
damaged.


18R&H27

7. Snap ring
• Install the spring compressor to the reverse and high
clutch drum.
• Use the spring compressor to carefully force the high
clutch cover down.
Spring compressor: 5-8840-2767-0
NOTE:
To avoid damage to the return springs, use only as much
force as is required to press the high clutch cover into
place.

19R&H28

•
Install the new snap ring to the reverse and high clutch
drum.

20R&H25

8. Dish plate, drive plates, driven plates, and retaining
plate
Install the high clutch dish plate (1), the 5 driven plates (2),
the 5 drive plates (3), and retaining plate (4).






RTW 47ASH000501

9. Snap ring
Install the snap ring.

NOTE:
Ensure the attachment direction of dish plate (1) is correct.

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ISUZU KB P190 2007

7A4-38 UNIT REPAIR (JR405E)

21R&H21

10.Dish plate, drive plates, driven plates, and retaining
plate Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).

248L300003

11.Snap ring
Install the snap ring.

NOTE:
Ensure the attachment direction of dish plate (1) is correct.

22R&H35

•
Install the reverse and high clutch drum to the oil pump
assembly.
• Force compressed air (390 kPa/4.0 kgf/cm
2/57 psi)
through the oil pump oil passages to check high clutch
operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


23CLEAR02

•
Measure the clearance between the high clutch 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).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)

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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-39
248L300004

5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)




24R&H34

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil pump oil passages to check reverse
clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


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ISUZU KB P190 2007

7A4-40 UNIT REPAIR (JR405E)

25CLEAR04

•
Measure the clearance between the reverse clutch
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).
Reverse clutch retaining plate and snap ring
clearance (B):
0.6~0.9 mm (0.024~0.035 in)
Available reverse clutch retaining plate thicknesses
4.8 mm (0.189 in)
5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)



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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-41
CARRIER AND LOW CLUTCH
ASSEMBLY

01C&L12
Legend
1. Snap ring
2. Front carrier
3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10. Bearing race
11. Snap ring
12. Retaining plate
13. Drive plate (7, low clutch)
14. Driven plate (6, low clutch)

15. Driven plate (1, 2 mm thick, low clutch)
16. Dish plate
17. Snap ring
18. Cancel cover
19. Return spring
20. Low clutch piston
21. Seal ring (small)
22. Seal ring (large)
23. Low clutch drum
24. Bearing
25. Snap ring
26. Low one-way clutch
27. Side plate
28. Snap ring

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ISUZU KB P190 2007

7A4-42 UNIT REPAIR (JR405E)

02C&L-SUB03

Disassembly steps
1. Snap ring
Remove the snap ring from the low clutch drum.


03C&L-SUB05

2. Front carrier
Remove the front carrier from the low clutch assembly.


04C&L-SUB06

3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10.Bearing race Remove the bearing (with bearing race), the rear sun gear,
the bearing, the rear carrier, the bearing race, the bearing,
and rear internal gear.

05C&L-SUB07












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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-43

06C&L-SUB08


07C&L-SUB09


08C&L-SUB10


09C&L-SUB11


10C&L-SUB12
• Remove the bearing race from the rear internal gear.


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ISUZU KB P190 2007