2007 ISUZU KB P190 oil

UNIT REPAIR (JR405E) 7A4-57

11CASE-AY01

5. Oil seal
Using a screwdriver, remove the oil seal from the
transmission case.




Inspection
2 – 4 brake drive plates
Measure the 2-4 brake drive plate facing thickness at 3
points and calculate the average value.
If the average value is less than the specified limit, the 2-4
brake drive plate must be replaced.
2 – 4 brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
Low and reverse brake drive plates
Measure the low and reverse brake drive plate facing
thickness at 3 points and calculate the average value.
If the average value is less than the specified limit, the lo
w
and reverse drive plate must be replaced.
Low and reverse brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
2 – 4 brake return springs
• Check the number of effective 2-4 brake return spring
coils.
Effective return spring coils (Standard): 10.2
• Measure the 2-4 brake return spring outside diameter,
free length, and linear diameter.
If any of the measured values exceed the specified limit,
the 2-4 brake return spring must be replaced.
2 – 4 brake return spring measurements (Standard):
Outside diameter = 6.9 mm (0.272 in)
Free length = 22.5 mm (0.886 in)
Linear diameter = 1.1 mm (0.043 in)
Low and reverse brake return springs
• Check the number of effective low and reverse brake
return spring coils.
Effective return spring coils (standard): 4.8
• Measure the low and reverse brake return spring outside
diameter, free length, and linear diameter.
If any of the measured values exceed the specified limit,
the low and reverse return spring must be replaced.
Low and reverse brake return spring measurements
(Standard):
Outside diameter = 11.2 mm (0.441 in)

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ISUZU KB P190 2007

7A4-58 UNIT REPAIR (JR405E)
Free length = 22.3 mm (0.878 in)
Linear diameter = 1.1 mm (0.043 in)


12CASE-AY06

Reassembly steps
1. Oil seal, manual shaft, and manual plate
• Use the oil seal installer to force the manual plate oil
seal into place.
Oil seal installer: 5-8840-2758-0


14CASE-AY21

•
Install the manual shaft together with the manual plate.


15CASE-AY26

•
Drive the spring pin into the transmission case.


16CASE-AY37

2. Parking rod
• Rotate the manual plate while installing the parking rod.


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ISUZU KB P190 2007

7A4-62 UNIT REPAIR (JR405E)





RTW 37AMF0001-X



36ASSY10

•
Install the retaining plate (4).


37ASSY011

•
Install the snap ring.


38L&R03

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil passages of the transmission case to
check low and reverse brake operation.
If the low and reverse brake does not operate, check the
seal rings for damage and replace if necessary. Also
check that no parts have been installed out of place.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-65

472-4B17

•
Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Be sure that the spring compressor is perfectly centered
(an off-center special tool will damage the return spring).
• Use the spring compressor to force the 2-4 brake
retainer.


482-4B18

NOTE:
To avoid damaging the return spring, apply as little force
as possible to the 2-4 brake retainer.
• Install the snap ring.


492-4B22

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil passages of the transmission case to
operate and break-in the 2-4 brake.


502-4B19

•
Measure the clearance between the 2-4 brake retainer
and the retaining plate.
If the clearance is outside the specified range, replace
the existing brake retainer with a new one of the prope
r
size (thickness).
2 – 4 brake retainer and retaining plate clearance:
1.0~1.4 mm (0.039~0.055 in)
Available 2-4 brake retaining plate thicknesses
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
6.2 mm (0.244 in)
6.4 mm (0.252 in)
• Use the spring compressor to release the 2-4 brake.



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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-69
AUTOMATIC TRANSMISSION
REASSEMBLY
Assembly cautions
• Use your bare hands or vinyl gloves to reassemble the
transmission. Do not use ordinary work gloves (loosen
threads from the gloves may fall into the transmission
and cause problems).
• Before installing the drive plates, immerse them in the
recommended automatic transmission fluid (BESCO
ATF III). If the drive plate is new, it must be immersed
for at least two hours to ensure oil penetration and
saturation of the facing.
•
Apply ATF to all sliding and contact surfaces before
assembly. Also apply ATF to seal rings and O-rings.
Assemble the parts carefully to avoid damaging them.
• Replace any snap ring that appears worn, bent out o
f
shape, or damaged.
• If any part contacting the transmission case is damaged,
it must be replaced with a new part.
• Be careful not to damage the plates during reassembl
y
(oil leakage from the plate will result).
• If you are reusing a seal, remove the old adhesive agent
and clean the surface with cleaning oil before applying
the new adhesive agent.
• W ait at least two hours after installing the oil seals
before installing the plates.
• Do not replace O-rings, snap rings, bearings, and/o
r
bearing races with inferior substitutes.


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ISUZU KB P190 2007

7A4-74 UNIT REPAIR (JR405E)

192-4B22

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the transmission case oil passage to 2-4 brake
operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing
• Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040
• Install the front sun gear to the transmission case.


22ASSY042
• Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-75

24ASSY047

•
Install the high clutch hub and the bearing race to the
transmission case.


25R&H42

11.Clutch pack (reverse and high clutch assembly)
• Install the bearing (with bearing race) to the clutch pack.
NOTE:
•
••
•
The black side (bearing race) of the bearing must
contact the clutch pack.
•
••
•
Apply Vaseline to the bearing.


26ASSY049

•
Install the clutch pack and bearing to the transmission
case.



27ASSY051

•
Install the bearing to the clutch pack.
NOTE:
Apply Vaseline to the bearing.







RTW 47ASH000101

Total end play measurement
• Install the bearing race (oil pump) to the clutch pack.
• Measure the distance (A) between the oil pump
installation surface and the bearing race.


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ISUZU KB P190 2007

7A4-76 UNIT REPAIR (JR405E)





RTW 47ASH000201

•
Measure the distance (B) between the bearing race
installation surface and the machined surface.
• Calculate the total end play using the following formula.
Total end play = distance (A) – distance (B)
If the measured and calculated end play is outside the
specified range, replace the existing bearing race with a
bearing race of the proper size (thickness).
Total end play = 0.25~0.55 mm (0.0098~0.0217 in)
Available oil pump bearing race thicknesses
1.4 mm (0.055 in)
1.6 mm (0.063 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)
2.2 mm (0.087 in)
2.4 mm (0.094 in)





RTW 47ASH000201


28ASSY058

12.Input shaft
Install the input shaft.


29PUMP02

13.Oil pump assembly
• Install a new O-ring to the outside of the oil pump.
• Install the bearing race to the oil pump.
NOTE:
Apply Vaseline to the bearing race.


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ISUZU KB P190 2007