torque ISUZU KB P190 2007 Workshop Repair Manual

7A3-36 ON-VEHICLE SERVICE (AW30–40LE)
Installation
To install, follow the removal steps in reverse order
noting the following point;
1. Reinstall the parts removed with the valve bod
y
assembly to their assigned positions in the
transmission case (check valve assembly, C0
accumulator pistons, etc). Install the valve bod
y
assembly to the transmission case.
Refer to REASSEMBLY OF MAJOR
COMPONENTS (2).
2. Solenoid clamp bolt
Torque : 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 Ib ⋅
⋅⋅
⋅
in)
3. Valve body fixing bolts
Each bolt location is indicated in the figure.
Torque : 10 N ⋅
⋅⋅
⋅
m (1.0 kgf ⋅
⋅⋅
⋅
m/87 Ib ⋅
⋅⋅
⋅
in)
NOTE: Tighten the bolts toward outside equally.




244R200078
4. Oil strainer fixing bolts
Torque : 10 N ⋅
⋅⋅
⋅
m (1.0 kgf ⋅
⋅⋅
⋅
m/87 Ib ⋅
⋅⋅
⋅
in)
5. Oil pan fixing bolts
Torque : 7.4 N ⋅
⋅⋅
⋅
m (0.75 kgf ⋅
⋅⋅
⋅
m/65 Ib ⋅
⋅⋅
⋅
in)



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-37
Rear Oil Seal (Adapter Housing, 4×
××
×4)

Removal
1. Remove the front and rear propeller shaft assembly
from the transfer case.
2. Remove the transfer case assembly from the transmission case.
Refer to Section 7D TRANSFER.
3. Using a screwdriver, remove the rear oil seal.
Installation
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the adapter housing.
Oil seal installer : 5-8840-2282-0






240RY00003
3. Install the transfer case assembly.
Refer to section 7D TRANSFER.
4. Install the front and rear propeller shaft assembly.
Torque (Propeller shaft flange bolt) :
63 N ⋅
⋅⋅
⋅
m (6.4 kgf ⋅
⋅⋅
⋅
m/46 Ib ⋅
⋅⋅
⋅
ft)




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ISUZU KB P190 2007

7A3-38 ON-VEHICLE SERVICE (AW30–40LE)
Rear Oil Seal (Extension Housing, 4×
××
×2)

Removal
1. Remove the rear propeller shaft assembly.
2. Using a screwdriver, remove the rear oil seal.
Installation
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the extension housing.
Oil seal installer : 5-8840-2702-0





249L100005
3. Install the rear propeller shaft.
Torque (Flange bolt): 63 N ⋅
⋅⋅
⋅
m (6.4 kgf ⋅
⋅⋅
⋅
m/46 Ib ⋅ft)



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-43
19.Remove the under cover (1).





RTW 77ASH002601
20.Remove the torque converter bolts by turning the
crank shaft.
21.Remove the four transmission bolts.
22.Disconnect the two fuel pipe clips (1) on the transmission crossmember left side.




RTW 77ASH002701
23.Support transmission assembly with a
transmission jack.





RTW 77BSH000401
24.Support engine assembly with a engine jack.
25.Remove the transmission crossmember. • Remove the transmission mount nuts.
• Remove the transmission crossmember bolts
and nuts.
26.Remove the transmission assembly from the vehicle.

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ISUZU KB P190 2007

7A3-44 ON-VEHICLE SERVICE (AW30–40LE)
Installation
1. Attach the transmission assembly to the engine.
• Slowly raise transmission jack until front of the
transmission assembly is aligned with rear o
f
the engine.
•
Attach the transmission assembly to the
engine.
• Tighten engine transmission bolts as shown in
the figure.





RTW 77ALF000701
2. Install the transmission crossmember.
• Install the transmission crossmember bolts and
nuts.

• Install the transmission mount nuts.
Torque: Crossmember ∼
∼∼
∼
Frame
･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･･
･
76 N ⋅
⋅⋅
⋅
m (7.8 kgf ⋅m/56 lb ⋅ft)
Crossmember ∼
∼∼
∼
Transmission mounting
･････････････
52 N⋅
⋅⋅
⋅
m (5.3 kgf ⋅m/38 lb ⋅ft)


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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-45
3. Remove a engine jack.
4. Remove a transmission jack.
5. Connect the two fuel pipe clips (1) on the transmission crossmember left side.




RTW 77ASH002701
6. Install the torque converter bolts.
Torque: 29 N ⋅
⋅⋅
⋅
m(3.0 kgf ⋅m/22 lb ⋅ft)
NOTE: Do not reuse the torque converter bolts.
7. Install the under cover(1). Torque: 8 N ⋅
⋅⋅
⋅
m(0.8 kgf ⋅m/69 lb ⋅in)





RTW 77ASH002601
8. Connect two ATF pipes.
Torque: 44 N ⋅
⋅⋅
⋅
m(4.5 kgf ⋅m/33 lb ⋅ft)
9. Install the ATF pipe bolt (1).




RTW 77ASH002501
10.Connect the starter assembly with shift cable
bracket.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)
11.Connect the shift cable bracket on the transmission side.
12.Install the fuel pipe bracket bolt (1) on clutch housing lower left side.
Torque: 76 N ⋅
⋅⋅
⋅
m(7.7 kgf ⋅m/56 lb ⋅ft)





RTW 77ASH002401
13.Install the oil level gauge and upper guide tube.



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-47



RTW 77ASH002201




RTW 77ASH002301

19.Install the transfer assembly.(4 ×4 only)
•
Apply a thin coat of molybdenum disulfide
grease to the input shaft spline.
Torque: 41 N ⋅
⋅⋅
⋅
m(4.2 kgf ⋅m/30 lb ⋅ft)





RTW 77ASH001701
20.Connect two harness clips (1) of the tansfer upper
side.



1
1


RTW 77ASH001601
21.Connect the speed sensor connector.


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ISUZU KB P190 2007

7A3-48 ON-VEHICLE SERVICE (AW30–40LE)
22.Connect the 2W D-4W D switch connector (1),
neutral switch connector (2), actuator connecto
r
(3) and speed sensor connector (4).





RTW 77ASH001801



RTW 77ASH001901






RTW 77ASH002001
23.Install the rear propeller shaft.
NOTE: Align alignment marks on the flange.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅m/43 lb ⋅ft)






RTW 77BSH000201
24.Install the center bearing on the crossmember.
Torque: 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅m/51 lb ⋅ft)
25.Install the front propeller shaft.(4 ×4 only)
NOTE: Align alignment marks on the flange.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅m/43 lb ⋅ft)
26.Remove the drain plug from oil pan and drain the fluid.
27.Install the drain plug. Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅m/14 lb ⋅ft)
28.Pour the transmission oil.
29.Remove suitable stands.
30.Connect battery ground cable.

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–1
SECTION 7A4
TABLE OF CONTENTS
UNIT REPAIR (AW30–40LE)
Major Components (1) ................................... 7A4–2Major Components (1) and Associatedparts ........................................................... 7A4–2
Disassembly steps ...................................... 7A4–2
Components (1) ............................................. 7A4–4 Reassembly ................................................ 7A4–4
Major Components (2) ................................... 7A4–6 Major Componets (2) and Associated Parts ........................................................... 7A4–6
Disassembly ............................................... 7A4–7
Reassembly ................................................ 7A4–10
Major Components (3) ................................... 7A4–15 Major Components (3) and AssociatedParts ........................................................... 7A4–15
Disassembly ............................................... 7A4–16
Reassembly ................................................ 7A4–24
Diaassembly, Inspection and Reassembly of minor Components ................................. 7A4–36
Oil Pump ........................................................ 7A4–37 Disassembly View ...................................... 7A4–37
Disassembly ............................................... 7A4–37
Inspection and Repair ................................. 7A4–38
Reassembly ................................................ 7A4–40
OD Planetary Gear and OD Direct Clutch Assembly (C–0).......................................... 7A4–42
Disassembled View .................................... 7A4–42
Disassembly ............................................... 7A4–43
Inspection and Repair ................................. 7A4–46
Reassembly ................................................ 7A4–47
OD Support Assembly ................................... 7A4–52 Disassembled View .................................... 7A4–52
Disassembly ............................................... 7A4–52
Inspection and Repair ................................. 7A4–53
Reassembly ................................................ 7A4–54
Direct Clutch Assembly (C-2) ........................ 7A4–57 Disassembled View .................................... 7A4–57
Disassembly ............................................... 7A4–58
Inspection and Repair ................................. 7A4–59
Reassembly ................................................ 7A4–60
Forward Clutch Asseembly (C-1)................... 7A4–63 Disassembled View .................................... 7A4–63
Disassembly ............................................... 7A4–64
Inspection and Repair ................................. 7A4–65 Reassembly ................................................ 7A4–66
Front Planetary Gear ..................................... 7A4–70 Disassembled View .................................... 7A4–70
Disassembly ............................................... 7A4–70
Inspection and Repair ................................. 7A4–70
Reassembly ................................................ 7A4–71
Planetary Sun Gear and No.1 One-Way Clutch ......................................................... 7A4–72
Disassembled View .................................... 7A4–72
Disassembly ............................................... 7A4–73
Inspection and Repair ................................. 7A4–73
Reassembly ................................................ 7A4–74
Second Brake Assembly (B–2) ...................... 7A4–76 Disassembled View .................................... 7A4–76
Disassembly ............................................... 7A4–76
Inspection and Repair ................................. 7A4–77
Reassembly ................................................ 7A4–77
Rear Planetary Gear Assembly and Output Shaft ........................................................... 7A4–80
Disassembled View .................................... 7A4–80
Disassembly ............................................... 7A4–81
Reassembly ................................................ 7A4–83
First and Reverse Brake (B–3) ...................... 7A4–86 Disassembled View .................................... 7A4–86
Disassembly ............................................... 7A4–87
Reassembly ................................................ 7A4–88
Transmission Case ........................................ 7A4–91 Disassembled View .................................... 7A4–91
Disassembly ............................................... 7A4–91
Reassembly ................................................ 7A4–92
Torque Converter........................................... 7A4–94 Inspection and Repair ................................. 7A4–94
Adapter Housing (4 × 4)................................. 7A4–95
Disassembled View .................................... 7A4–95
Disassembly ............................................... 7A4–95
Reassembly ................................................ 7A4–95
Extension Housing (4 × 2) ............................. 7A4–96
Disassembled View .................................... 7A4–96
Disassembly ............................................... 7A4–96
Reassembly ................................................ 7A4–97
Main Data and Specifications ........................ 7A4–98
Special Tools ................................................. 7A4–102

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7A4–2 UNIT REPAIR (AW30–40LE)
Major Components (1)
Major Components (1) and Associated parts
RTW77AMF003801
EndOFCallout
Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
Legend (1) Torque converter
(2) Neutral start switch
(3) Elbow
(4) Oil temperature sensor
(5) Breather hose (6) Output revolution sensor
(7) Adapter housing
(8) Transmission assembly
(9) Select lever
(10) Input revolution sensor

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ISUZU KB P190 2007