torque ISUZU KB P190 2007 Workshop Repair Manual

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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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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7A4–50 UNIT REPAIR (AW30–40LE)
13. Install two plates and two discs then install theflange, with the flat side facing downward.
252L100013
14. Install snap ring.
252L100014
15. 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.
252L100005Using a dial indicator, measure the OD direct clutch
piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
252L100016
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)

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7A4–94 UNIT REPAIR (AW30–40LE)
Torque Converter
Inspection and Repair
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : 5-8840-2168-0
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.
241RY00018
1. One-way clutch test. The clutch should lock when turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5 N ·m (0.25kgf ·m/22 Ib ·in) of
torque should be required to rotate the clutch
clockwise. If necessary, clean the converter and
retest the clutch. Replace the conver ter if the clutch
still fails the test.

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ISUZU KB P190 2007

7A4–98 UNIT REPAIR (AW30–40LE)
Main Data and Specifications
General Specifications
Remaks
Model AW30–40LE
Engine 4JJ1-TC High Output (3.0L)
Type Electronic control planetary gear type
3–element 1 –stage 2 –phase type
(with lock-up mechanism)
Gear ratio 1st 2.804
2nd 1.532
3rd 1.000
4th (O/D) 0.705
Reverse 2.394
Oil used Name Exxon Mobil ATF-3309
Q'ty (l) 8.7
Torque conver ter 2300 ± 200 Stall speed (rpm)
Friction element Forward clutch C–16
Number of discs
Direct clutch C–25
OD direct clutch C–03
Second coast brake B–1 40 mm Band width or
Number of discs
Second brake B–25
Number of discs
First and reverse brake B–37
Overdrive brake B–05
Clutch One-way clutch No.1 F–12 2
Number of
sprage
One-way clutch No.2
F–22 8
OD one-way clutch F–02 4
Planetary gear Front planetary Sun gear 42
Number of teeth
Pinion gear
19
Ring gear 79
Rear planetary Sun gear 33
Pinion gear 23
Ring gear 79
O/D planetary Sun gear 33
Pinion gear 23
Ring gear 79

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UNIT REPAIR (AW30–40LE) 7A4–99
Torque Specifications
N·m (kgf ·m/Ib ·ft)
RTW77ALF001901

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7A4–100 UNIT REPAIR (AW30–40LE)
Torque Specifications (Cont'd)
N·m (kgf ·m/Ib ·ft)
RTW77ALF002201

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UNIT REPAIR (AW30–40LE) 7A4–101
Torque Specifications (Cont'd)
N·m (kgf ·m/Ib ·ft)
RTW77ALF002301

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7A4–102 UNIT REPAIR (AW30–40LE)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5-8840-2152-0 (J–37227)
Holding fixture
5-8840-0003-0 (J –3289 –20)
Holding fixture base
5-8840-2153-0(J–37228)
Oil pan seal cutter
5-8840-0195-0(J –23327 –1)
Spring compressor
5-8840-2256-0(J–9617)
Oil seal installer; oil pump
5-8840-2170-0 (J–37233)
Spring compressor; OD brake piston
5-8840-0093-0(J –29770 –A)
Oil pressure gauge
5-8840-0254-0(J–25048)
Spring compressor
5-8840-2173-0(J–37236)
Reaction sleeve puller; first and reverse brake
5-8840-2174-0(J–37237)
Piston puller; first and reverse brake
5-8840-2169-0 (J –37232 –2)
Oil seal installer;
manual valve shaft seal installer & remover
5-8840-2168-0(J–35467)
Onennway clutch
testing tool; torque converter
ILLUSTRATION
TOOL NO.
TOOL NAME

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