2007 ISUZU KB P190 oil

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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ISUZU KB P190 2007

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

UNIT REPAIR (AW30–40LE) 7A4–3
3. Remove the neutral start switch (Mode switch). Unstake the lock washer.
 Remove the nut and bolt, and then remove the
neutral start switch.
 Remove the lock washer.
RTW77ASH003401
4. Remove the two elbows from transmission case.
240RY00001
5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4 ×4).
9. Remove the output revolution sensor (4 ×2).
10. Remove the speedometer sensor, speedometer driven gear and plate (4 ×2).
11. Remove the extension housing (4 ×2).
12. Remove the adapter housing (4 ×4). 13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (1)
Holding fixture base: 5-8840-0003-0 (2)
RTW77ASH003301

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ISUZU KB P190 2007

7A4–4 UNIT REPAIR (AW30–40LE)
Components (1)
Reassembly
1. Install a new gasket and the extension housing(4×2) to the transmission case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
2. Install the speedometer driven gear, plate, and speedometer sensor (4 ×2).
Torque:
Plate bolt – 15 N·m (1.5 kgf·m/11 Ib ·ft)
Speedometer sensor – 25 N·m (2.5 kgf·m/18 Ib ·ft)
3. Install the adapter housing (4 ×4).
 Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
241RY00020
 Apply liquid gasket (TB1281 –B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
 Install the adapter housing to the transmission
case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
4. Install the neutral start switch.  Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
 Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
 Install the lock washer and nut.
Torque: 7 N·m (0.7 kgf·m/61 Ib ·in) 
Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (1.3 kgf·m/113 Ib ·in)
 Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW17ASH013601
5. Install the oil temperature sensor to the transmission case.
Torque: 15 N·m (1.5 kgf·m/11 Ib ·ft)
RTW77ASH003501

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ISUZU KB P190 2007

7A4–6 UNIT REPAIR (AW30–40LE)
Major Components (2)
Major Componets (2) and Associated Parts
RTW77ALF001701
EndOFCallout
Legend(1) Converter housing
(2) Snap ring, rotor, key
(3) Speedometer shaft sleeve
(4) Speedometer drive gear
(5) Speedometer driven gear
(6) Valve body
(7) Check valve, spring, ball
(8) Spring (9) Accumulator piston (C
–0), O-ring
(10) Accumulator piston (B –0), O-ring
(11) Spring
(12) Accumulator piston (C –2), O-ring
(13) Spring
(14) Accumulator piston (B –2), O-ring
(15) Spring
(16) Oil strainer assembly
(17) Oil pan

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–7
Disassembly
1. Remove the six bolts and remove the converterhousing.
240R200022
2. Remove the oil pan.
NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove the nineteen bolts.
 Remove oil pan by lifting the transmission case.
Oil pan seal cutter: 5-8840-2153-0
RUW37ASH002901
3. Examine particles in oil pan.
 Remove the magnet and use it to collect any
steel chips. 
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear
240RY00008
4. Remove the oil strainer assembly. Remove four bolts holding the oil strainer.
244RY00003

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–9
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C –2).
 Remove accumulator pistons and springs from
transmission case.
240RY00010
10. Applying compressed air to the oil hole, remove the B–0 accumulator piston and spring.
240RY00011
11. Remove the C –0 accumulator piston.
240RY00012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
 Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4 ×4).
 Remove the snap ring from the output shaft.
 Remove the rotor and key.
247R200002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4 ×2).
 Remove the snap ring from the output shaft.
 Remove the speedometer sensor drive gear, and
ball.

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ISUZU KB P190 2007