2007 ISUZU KB P190 indicator

7A4–32 UNIT REPAIR (AW30–40LE)
Install and tighten the two bolts.
Torque: 25 N ·m (2.5 kgf ·m / 18 lb ·ft)
252RY00004
26. Check end of output shaft.
Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)
247RY00020
27. Install the (flat ring) 4.0 mm (0.157 in) thick flange
with the rounded edge side of the flange facing the
disc.
Alternately install four discs and four plates. (Disc
first)
252RY00009
28. Install the (stepped ring) flange with the flat side of the flange facing the disc.
Install the snap ring.
Snap ring (Reference)
246RY00001
Inside diameter 167.9 mm (6.61 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–33
29. Check piston stroke of overdrive brake.Place a dial indicator onto the overdrive brake
piston as shown in the figure.
252RY00003Measure the stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure.
Piston stroke: 1.75 – 2.05 mm (0.0689 – 0.0807 in)
If the values are nonstandard, check for an improper
installation.
Available flange size
244RY00001
Remove the snap ring.
246RY00001Remove one flange, four plates and four discs.
246RY00026
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

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ISUZU KB P190 2007

7A4–38 UNIT REPAIR (AW30–40LE)
2. Remove the O-ring.
3. Remove the stator shaft.
4. Remove the oil pump drive gear.
5. Remove the oil pump driven gear.
6. Remove the oil pump body. Remove 13 bolts, and then remove the stator shaft
from oil pump body.
Then remove drive and driven gear.
241RY00006
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check oil pump body bushing. Using a dial indicator, measure the inside diameter
of the oil pump body bushing.
Maximum inside diameter: 38.19 mm (1.5035 in) If the inside diameter is greater than the maximum,
replace the oil pump body.
241RY00007
2. Check stator shaft bushing. Using a dial indicator, measure the inside diameter
of the stator shaft bushing.
Maximum inside diameter: Front side: 21.58 mm
(0.8496 in)
Maximum inside diameter: Rear side: 27.08 mm
(1.0661 in)
If the inside diameter is greater than the maximum,
replace the stator shaft.
241RY00008
3. Check tip clearance of both gears. Measure between the gear teeth and the
cresent-shaped part of the pump body.
Standard tip clearance: 0.11 – 0.14 mm (0.0043 –
0.0055 in)
Maximum tip clearance: 0.19 mm (0.0075 in) If the tip clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
241RY00009

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–43
Disassembly
1. Check operation of one-way clutch.Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW37ASH004501
2. Remove OD direct clutch assembly from OD planetary gear assembly.
252L100004
3. Then remove thrust bearing with the race from ODdirect clutch drum. 4. 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.
252L100005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
252L100016

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ISUZU KB P190 2007

7A4–46 UNIT REPAIR (AW30–40LE)
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in) If the thickness is less than the minimum, replace
the disc.
252RY00027
2. Check piston return spring Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
252RY00028
3. Check OD direct clutch piston. Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
252RY00029
4. Check OD direct clutch drum bushings. Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in) If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
252L100009

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–47
5. Check OD planetary gear bushing.Using a dial indicator, measure the inside diameter
of replace the OD planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.4437 in) If the inside diameter is greater than the maximum,
replace the OD planetary gear.
252RY00031
Reassembly
1. Install the thrust washer to the OD planetary gear, facing the grooved side upward.
252RY00032
2. Install the one-way clutch into the outer race, withthe flanged side of the one-way clutch facing
upward.
252RY00033
3. Install OD one-way clutch with outer race to overdrive planetary gear.
252RY00026

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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

7A4–58 UNIT REPAIR (AW30–40LE)
Disassembly
Remove direct clutch drum assembly from forward
clutch assembly.
248RY00028
1. Check piston stroke of direct clutch (C –2).
Place the direct clutch assembly onto the OD
support assembly.
248RY00029
Using a dial indicator, measure the direct clutch
piston stroke by applying and releasing compressed
air (390 – 780 kPa or 57 – 114 psi) as shown.
Pack clearance: 0.5 – 0.8 mm (0.020 – 0.031 in)
RUW37ASH004901
2. Remove the clutch drum thrust washer (Plastic)
from the rear end of direct clutch.
3. Remove the snap ring from the direct clutch drum.
4. Remove the flange, plates and discs.
5. Place special tool on the spring retainer and compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : 5-8840-0254-0
248RY00002
6. Remove the piston return spring.

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ISUZU KB P190 2007