2007 ISUZU KB P190 oil

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

7A4–52 UNIT REPAIR (AW30–40LE)
OD Support Assembly
Disassembled View
RTW77AMF000301
EndOFCallout
Disassembly
1. Check OD brake piston movement.Place the OD support assembly onto the direct
clutch assembly.
252RY00042
Legend
(1) Snap ring
(2) Piston return spring
(3) O-ring (4) OD brake piston
(5) OD support
(6) Oil seal ring

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–53
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
252RY00043
2. Remove the thrust bearing.
3. Remove the race.
4. Remove the thrust washer (plastic).
5. Place special tool on the spring retainer, and compress the return spring with a shop press.
Spring compressor : 5-8840-2170-0 Remove the snap ring with a screwdriver.
252RY00044
6. Romove the piston return spring. 7. Place the OD support onto the direct clutch
assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
252RY00045
8. Remove the O-ring and oil seal rings from OD support.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring Using calipers, measure the free length of the return
spring.
Standard length: 17.2 mm (0.677 in)
252RY00046

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ISUZU KB P190 2007

7A4–54 UNIT REPAIR (AW30–40LE)
Reassembly
1. Coat the two oil seal rings with ATF.Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.
252RY00047
2. Coat two new O-rings with ATF and install them on the OD brake piston.
3. Being careful not to damage the O-rings, press the brake piston into the OD support, using both hands.
252RY00048
4. Install piston return spring.
252RY00049
5. Place special tool on the spring retainer, andcompress the return spring with a shop press.
Spring compressor : 5-8840-2170-0
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
with cutout portion of the OD support.
252RY00050

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ISUZU KB P190 2007

7A4–56 UNIT REPAIR (AW30–40LE)
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
252RY00043

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–63
Forward Clutch Asseembly (C-1)
Disassembled View
RTW77ALF001001
EndOFCallout
Legend(1) Race
(2) Thrust bearing
(3) Oil seal ring
(4) Forward clutch drum
(5) O-ring
(6) Piston
(7) O-ring
(8) O-ring (9) Piston return spring
(10) Snap ring
(11) Race
(12) Thrust bearing
(13) Snap ring
(14) Flange
(15) Plate and disc Six plates and six discs
(16) Cushion plate

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–65
5. Place special tool on the spring retainer andcompress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : 5-8840-0254-0
248RY00003
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD suppor t. Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
248RY00042
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from forward clutch drum.
Inspection and Repair
1. Check forward clutch pistonCheck that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
248RY00031
2. Check forward clutch drum bushing. Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 in) If the inside diameter is greater then the maximum,
replace the forward clutch drum.
248RY00043
3. Check disc, plate and flange. Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
 If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.

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ISUZU KB P190 2007