2007 ISUZU KB P190 ECO mode

7A4–30 UNIT REPAIR (AW30–40LE)
Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
Assembled bearing and race diameter
(Reference)
248RY00025
20. Assembly second coast brake piston assembly. Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
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21. Coat two new oil seals with ATF and install them to the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
248RY00027
22. Check piston stroke of second coast brake Place a mark on the second coast brake piston rod
as shown in the figure.
248RY00005Using wire gauge, measure the stroke by applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)
Inside
Outside
Bearing
and race 33.7 mm (1.33 in) 47.8 mm (1.88 in)
Legend (1) Second coast brake piston
(2) Oil seal
(3) Piston rod

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ISUZU KB P190 2007

7A4–36 UNIT REPAIR (AW30–40LE)
Diaassembly, Inspection and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the next
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:
1. All disassembled parts should be washed clean and any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged inproper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in place.

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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.
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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.
248RY00053
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.
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Legend
(1) Free
(2) Lock

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ISUZU KB P190 2007

7A4–76 UNIT REPAIR (AW30–40LE)
Second Brake Assembly (B–2)
Disassembled View
246R200001
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Disassembly
1. Remove second brake assembly from output shaft.
246RY00007
Legend(1) Second brake assembly
(2) Thrust washer (Plastic)
(3) Snap ring
(4) Spring retainer (5) Piston return spring
(6) Piston sleeve
(7) Second brake piston
(8) O-ring
(9) Second brake drum

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–77
2. Remove the hrust washer (plastic).
3. Place special tool on the spring retainer, and compress the return spring.
Spring compressor: 5-8840-0254-0
Remove the snap ring with snap ring pliers.
247RY00001
4. Remove the spring retainer and piston return spring.
5. Romove piston sleeve.
6. Holding the second brake piston by hand, apply compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
246RY00008
7. Remove the o-rings from the second brake piston.
Inspection and Repair
1. Check piston return spring. Using calipers, measure the free length of the return
spring.
Standard length: 18.38 mm (0.724 in)
247RY00034
Reassembly
1. Coat new O-rings with ATF and install them on the second brake piston.
246RY00009
2. Being careful not to damage the O-rings, press inthe second brake piston into the second brake
drum.
3. Install piston sleeve.

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ISUZU KB P190 2007

7A4–78 UNIT REPAIR (AW30–40LE)
4. Install piston return spring.
246RY00010
5. Install spring retainer.
6. Place special tool on the spring retainer, and compress the return spring.
Spring compressor: 5-8840-0254-0
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
247RY00001
7. Check second brake piston movement. Make sure the second brake piston moves smoothly
when applying and releasing the low compressed
air to the second brake drum.
246RY00011
8. Coat the thrust washer (plastic) with petroleum jelly and install it to the second brake piston, with the
grooved side facing upward.
NOTE: Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
246RY00012

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–79
9. Install second brake assembly to output shaft.
246RY00014

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ISUZU KB P190 2007