2007 ISUZU KB P190 clock

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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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–51
16. Coat the assembled bearing and race withpetroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
252L100015
17. Align the flukes of discs in the direct clutch. Install the OD direct clutch assembly onto the OD
planetary gear.
252L100004
18. 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
En dOFCallout
Inside diameter 28.9 mm (1.138 in)
Outside diameter 50.2 mm (1.976 in)
Legend (1) Free
(2) Lock

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–73
Disassembly
1. Check operation of No.1 one-way clutchHold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW37ASH004601
E ndOFCallout
2. Remove the one-way clutch and second brake hub.
3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).
248RY00052
5. Remove the snap ring with snap ring pliers.
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6. Remove the sun gear input drum.
7. Remove the snap ring from planetary sun gear.
Inspection and Repair
1. Check planetary sun gear bushing Using a dial indicator, measure the inside diameter
of the planetary sun gear bushing.
Maximum inside diameter: 27.08 mm (1.066 in) If the inside diameter is greater than the maximum,
replace the planetary sun gear.
248RY00054
Legend
(1) Free
(2) Lock

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–75
5. Install thrust washer (plastic).
NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
248RY00057
6. Install assembled No.1 one-way clutch and second brake hub onto planetary sun gear as shown.
248RY00058
7. Check operation of No.1 one-way clutchHold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
RUW37ASH004601
En dOFCallout
Legend
(1) Free
(2) Lock

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–81
Disassembly
1. Remove second brake assembly from output shaft.
246RY00014
2. Remove oil seal ring from output shaft.
247RY00028
3. Remove the seven discs, seven plates and flange(B–3). 4. Remove rear planetary gear from rear planetary ring
gear.
247RY00029
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.
RUW37ASH004701
En dOFCallout
Legend
(1) Lock
(2) Free

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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.
247RY00040
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.
RUW37ASH004701
E ndOFCallout
9. Install rear planetary gear onto rear planetary ring gear.
247RY00029
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.
246RY00013
Legend
(1) Lock
(2) Free

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ISUZU KB P190 2007

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

CONSTRUCTION AND FUNCTION 7A1-13

2-4 Brake and Low & Reverse Brake (Multi-Plate Brake) • The multi-plate brake is composed of drive plates and driven plates. By applying the oil pressure onto
the end surface of the plates, the clutch is engaged. The oil pressure is adjusted with the control valve
according to the signal from the TCM.
• All brakes use dish plates to prevent uncontrolled operation of the clutches when engaged, causing a
shock.
• The solenoid in the control valve is driven based on the shift signal from TCM, it moves the shift valve,
thereby engaging the drive plate and driven plate through the piston of each clutch.
• As a result, rotation of each element of the planetary gear unit is fixed.
• When the oil pressure is removed, the piston returns to the original position via the force of the return
spring.




Figure 19. Construction of 2-4 Brake
Figure 20. Construction of Low & Reverse Brake

Low One-way Clutch
• The low one-way clutch employs the sprag, which locks the counterclockwise rotation of the front
planetary carrier and the rear internal gear.
• The one-way clutch outer race is fitted with the low clutch drum, and the inner race is fitted with the
transmission case.
• The outer race rotates freely clockwise, but, when it attempts to rotate counterclockwise, the sprag locks
the outer race.
• When the vehicle is traveling in 1st gear in the D, 3 or 2 position, the low one-way clutch locks the rear
internal gear via the low clutch. It is left free in the 2nd, 3rd or 4th gear.


Figure 21. Construction of Low One-way Clutch

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ISUZU KB P190 2007