2007 ISUZU KB P190 brake

UNIT REPAIR (AW30–40LE) 7A4–11
5. Install the second brake drum gasket. Install a new second brake drum gasket to the
transmission case.
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6. Individual piston operation inspection. Check for the sound of operation while injecting
compressed air into the oil hole indicated in the
figure.
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E ndOFCallout
NOTE: When inspecting the direct clutch, check with
the C –0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the parts. 7. Install the accumulator pistons.
 Coat the O –ring with ATF and install it to the
piston.
Install the three springs and four accumulator
pistons to the bore as shown in th figure.
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mm (in)
Legend (1) OD direct clutch
(2) Direct clutch
(3) Forward clutch
(4) OD brake
(5) Second coast brake
(6) Second brake
(7) First and reverse brake
(A) C –0 Accumulator piston hole
Piston Outer diameter Height
B –2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C –2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B –0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C –0 29.8 mm (1.173 in) 44.0 mm (1.732 in)
Spring Free length Outer diameterColor
B –2 75.8 (2.984) 20.1 (0.791) PURPLE
C –2
(Outer) 64.0 (2.520) 20.3 (0.799) WHITE&
PINK
C –2 (Inner) 42.1 (1.657) 14.7 (0.579) PINK
B –0 62.0 (2.441) 16.0 (0.630) GREEN
C –0
(Outer) 74.6 (2.937) 20.9 (0.823) ORANGE
C –0 (Inner) 46.0 (1.811) 14.0 (0.551) YELLOW

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–15
Major Components (3)
Major Components (3) and Associated Parts
RTW77ALF001801
EndOFCallout
Legend(1) Oil pump
(2) Race
(3) OD planetary gear and OD direct clutch
(4) Race
(5) OD planetary ring gear
(6) Snap ring
(7) Flange, plate and disc (B –0)
(8) Bearing and race
(9) Snap ring
(10) OD support
(11) Race
(12) Snap ring
(13) Second coast brake piston assembly
(14) Direct clutch and forward clutch (15) E-ring and pin
(16) Second coast brake band
(17) Front planetary ring gear
(18) Bearing and race
(19) Race
(20) Snap ring
(21) Front planetary gear
(22) Drum and one-way clutch
(23) Snap ring
(24) Flange, plate and disc (B –2)
(25) Snap ring
(26) Rear planetary gear, second brake drum and output shaft
(27) Bearing

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–17
5. Remove the overdrive planetary ring gear from thetransmission case.
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6. Check piston stroke of overdrive brakePlace a dial indicator onto the overdrive brake
piston as shown in the figure.
252RY00003Measure the stroke 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, select another flange. Available flange sizes
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7. Remove the snap ring.
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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

UNIT REPAIR (AW30–40LE) 7A4–19
Install two removed bolts to the OD support, and
pull out the OD suppor t assembly.
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12. Remove the race from OD support.
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13. Check piston stroke of second coast brake (B –1)
Place a mark on the second coast brake piston rod
as shown in the figure.
Using feeler gauge, measure the stroke 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)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band. There are two piston rods.
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Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)

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ISUZU KB P190 2007

7A4–20 UNIT REPAIR (AW30–40LE)
14. Using snap ring pliers, remove the snap ring.
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15. Applying compressed air to the oil hole, remove thesecond coast brake piston assembly.
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16. Remove the direct clutch and forward clutch fromthe transmission case.
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17. Remove the E-ring from the pin.Remove the pin from the brake band.
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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–21
18. Remove the second coast brake band from thetransmission case.
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19. Remove the front planetary ring gear from thetransmission case.
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20. Remove the bearing and race.
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21. Remove the race.
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22. Using snap ring pliers, remove the snap ring.
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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–23
27. Check pack clearance of first and reverse brake (B–
3)
Using a feeler gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.70 – 1.22 mm (0.0276 – 0.0480)
If the values are nonstandard, replace the discs.
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28. Using snap ring pliers, remove the snap ring.
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29. Remove the rear planetary gear, second brake drum and output shaft as an assembly.
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30. Remove the assembled thrust bearing and racefrom the transmission case.
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ISUZU KB P190 2007

7A4–24 UNIT REPAIR (AW30–40LE)
Reassembly
1. Coat the assembled bearing and race withpetroleum jelly and install it onto the transmission
case.
Assembled bearing and race (Reference)
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2. Install the rear planetary gear, second brake drum and output shaft.
 Align the teeth of the second brake drum,
flanges, discs and plates as shown in the figure.
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 Align the splines of the transmission case and the
assembled rear planetary gear, second brake
drum and output shaft, indicated by A in the
figure.
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3. Using snap ring pliers, install the snap ring.
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Bearing and race Diameter
Inside 39.38 mm (1.550 in)
Outside 58.15 mm (2.289 in)

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ISUZU KB P190 2007