Page 4512 of 6020
UNIT REPAIR (JR405E) 7A4-35
Return springs • Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2
• Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)
10R&H40
Reverse clutch piston
• Apply compressed air (390 kPa/4.0 kgf/cm
2/57 psi) to
the reverse clutch piston from the outside to the inside.
The flow of air should be blocked.
11R&H44
•
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.
12R&H39
Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.
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ISUZU KB P190 2007
Page 4513 of 6020
7A4-36 UNIT REPAIR (JR405E)
13R&H38
2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.
RTW 47ASH000601
As shown in a figure, oil seal lip is attached.
14R&H32
3. Reverse clutch piston
Install the reverse clutch piston to the reverse and high
clutch drum.
15R&H31
4. High clutch piston
Install the high clutch piston to the reverse clutch piston.
16R&H33
5. Return spring
Install the return spring to the high clutch piston.
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ISUZU KB P190 2007
Page 4515 of 6020
7A4-38 UNIT REPAIR (JR405E)
21R&H21
10.Dish plate, drive plates, driven plates, and retaining
plate Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).
248L300003
11.Snap ring
Install the snap ring.
NOTE:
Ensure the attachment direction of dish plate (1) is correct.
22R&H35
•
Install the reverse and high clutch drum to the oil pump
assembly.
• Force compressed air (390 kPa/4.0 kgf/cm
2/57 psi)
through the oil pump oil passages to check high clutch
operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.
23CLEAR02
•
Measure the clearance between the high clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)
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ISUZU KB P190 2007
Page 4516 of 6020
UNIT REPAIR (JR405E) 7A4-39
248L300004
5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)
24R&H34
•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil pump oil passages to check reverse
clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.
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ISUZU KB P190 2007
Page 4522 of 6020
UNIT REPAIR (JR405E) 7A4-45
30C&L-SUB21
15.Return spring
Remove the return spring.
15C&L-SUB38
16.Low clutch piston
• Insert the low one-way clutch inner race to the low clutch
drum.
• Force compressed air through the oil passages of the
low one-way clutch inner race to remove the low clutch
piston.
29C&L-SUB22
16C&L-SUB25
17.Snap ring
• Raise the low one-way clutch side.
• Remove the low one-way clutch snap ring.
17C&L-SUB27
18.Side plate
Remove the side plate.
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ISUZU KB P190 2007
Page 4523 of 6020
7A4-46 UNIT REPAIR (JR405E)
18C&L-SUB28
19.Low one-way clutch
Remove the low one-way clutch.
19C&L-SUB29
20.Snap ring
Remove the snap ring from the low clutch drum.
20C&L-SUB31
21.Bearing
Remove the bearing.
Inspection
Drive plates
• Measure the drive plate facing thickness at 3 points.
• Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)
Return springs
• Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 9.9
• Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 9.7 mm (0.382 in)
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ISUZU KB P190 2007
Page 4527 of 6020
7A4-50 UNIT REPAIR (JR405E)
34C&L-SUB15
10.Dish plate, drive plates, driven plates, and retaining
plate Install the low clutch dish plate (1), the 2 mm thick driven
plate (2), the 7 drive plates (3), the other 6 driven plates (4),
and the retaining plate (5).
NOTE:
The dish plate side with the identification mark must face
the driven plate.
248L300006
11.Snap ring
Install the snap ring to the low clutch drum.
NOTE:
Ensure the attachment direction of dish plate is correct.
35C&L-SUB38
36CLEAR06
Inspection
• Insert the low one-way clutch inner race to the low clutch
drum.
• Force compressed air (390 kPa/4.0 kgf/cm
2/57 psi)
through the oil passages of the low one-way clutch inne
r
race to check low clutch operation.
If the low clutch does not operate, the seal rings may be
damaged or the parts may have been installed in the
wrong order.
• Measure the clearance between the low clutch retaining
plate and the snap ring.
If the clearance is outside the specified range, replace
the existing plate with a new plate of the proper size
(thickness).
Low clutch retaining plate and snap ring clearance:
0.9~1.3 mm (0.035~0.051 in)
Available low clutch retaining plate thicknesses
3.8 mm (0.150 in)
4.0 mm (0.157 in)
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ISUZU KB P190 2007
Page 4531 of 6020
7A4-54 UNIT REPAIR (JR405E)
TRANSMISSION CASE
02CASE-BK06
Legend
1. Transmission case
2. Spring pin (slender)
3. Spring pin (fat)
4. Manual plate
5. Detent spring
6. Parking rod
7. Manual shaft
8. Oil seal
9. Inhibitor switch
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ISUZU KB P190 2007
