Page 4137 of 6020
7A4–2 UNIT REPAIR (AW30–40LE)
Major Components (1)
Major Components (1) and Associated parts
RTW77AMF003801
EndOFCallout
Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
Legend (1) Torque converter
(2) Neutral start switch
(3) Elbow
(4) Oil temperature sensor
(5) Breather hose (6) Output revolution sensor
(7) Adapter housing
(8) Transmission assembly
(9) Select lever
(10) Input revolution sensor
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ISUZU KB P190 2007
Page 4138 of 6020
UNIT REPAIR (AW30–40LE) 7A4–3
3. Remove the neutral start switch (Mode switch). Unstake the lock washer.
Remove the nut and bolt, and then remove the
neutral start switch.
Remove the lock washer.
RTW77ASH003401
4. Remove the two elbows from transmission case.
240RY00001
5. Remove the oil temperature sensor.
6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4 ×4).
9. Remove the output revolution sensor (4 ×2).
10. Remove the speedometer sensor, speedometer driven gear and plate (4 ×2).
11. Remove the extension housing (4 ×2).
12. Remove the adapter housing (4 ×4). 13. Remove the transmission assembly.
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (1)
Holding fixture base: 5-8840-0003-0 (2)
RTW77ASH003301
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Page 4139 of 6020

7A4–4 UNIT REPAIR (AW30–40LE)
Components (1)
Reassembly
1. Install a new gasket and the extension housing(4×2) to the transmission case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
2. Install the speedometer driven gear, plate, and speedometer sensor (4 ×2).
Torque:
Plate bolt – 15 N·m (1.5 kgf·m/11 Ib ·ft)
Speedometer sensor – 25 N·m (2.5 kgf·m/18 Ib ·ft)
3. Install the adapter housing (4 ×4).
Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
241RY00020
Apply liquid gasket (TB1281 –B or its equivalent)
(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
Install the adapter housing to the transmission
case.
Torque: 36 N·m (3.7 kgf·m/27 Ib ·ft)
4. Install the neutral start switch. Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
Install the lock washer and nut.
Torque: 7 N·m (0.7 kgf·m/61 Ib ·in)
Align the neutral standard line and the switch
groove and tighten the adjusting bolt.
Torque: 13 N·m (1.3 kgf·m/113 Ib ·in)
Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
RUW17ASH013601
5. Install the oil temperature sensor to the transmission case.
Torque: 15 N·m (1.5 kgf·m/11 Ib ·ft)
RTW77ASH003501
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ISUZU KB P190 2007
Page 4140 of 6020
UNIT REPAIR (AW30–40LE) 7A4–5
6. Install the elbow. Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29 N ·m (3.0 kgf ·m/22 Ib ·ft)
RTW77ASH003601
7. Install the select lever.
8. Install the output revolution sensor (4 ×2).
9. Install the output revolution sensor (4 ×4).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter. Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5 mm (0.53 in)
240RY00005
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Page 4141 of 6020
7A4–6 UNIT REPAIR (AW30–40LE)
Major Components (2)
Major Componets (2) and Associated Parts
RTW77ALF001701
EndOFCallout
Legend(1) Converter housing
(2) Snap ring, rotor, key
(3) Speedometer shaft sleeve
(4) Speedometer drive gear
(5) Speedometer driven gear
(6) Valve body
(7) Check valve, spring, ball
(8) Spring (9) Accumulator piston (C
–0), O-ring
(10) Accumulator piston (B –0), O-ring
(11) Spring
(12) Accumulator piston (C –2), O-ring
(13) Spring
(14) Accumulator piston (B –2), O-ring
(15) Spring
(16) Oil strainer assembly
(17) Oil pan
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ISUZU KB P190 2007
Page 4142 of 6020
UNIT REPAIR (AW30–40LE) 7A4–7
Disassembly
1. Remove the six bolts and remove the converterhousing.
240R200022
2. Remove the oil pan.
NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove the nineteen bolts.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: 5-8840-2153-0
RUW37ASH002901
3. Examine particles in oil pan.
Remove the magnet and use it to collect any
steel chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear
240RY00008
4. Remove the oil strainer assembly. Remove four bolts holding the oil strainer.
244RY00003
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Page 4143 of 6020
7A4–8 UNIT REPAIR (AW30–40LE)
5. Remove the valve body. Disconnect the connectors from the solenoid S1
(1), S2 (2), lock-up solenoid (3) and pressure
control solenoid (4).
249RY00011
249RY00012
Remove the twenty bolts from valve body.
244R200078
6. Remove the check valve and spring.
7. Remove two springs from C –0 accumulator piston.
240RY00028
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ISUZU KB P190 2007
Page 4144 of 6020
UNIT REPAIR (AW30–40LE) 7A4–9
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C –2).
Remove accumulator pistons and springs from
transmission case.
240RY00010
10. Applying compressed air to the oil hole, remove the B–0 accumulator piston and spring.
240RY00011
11. Remove the C –0 accumulator piston.
240RY00012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4 ×4).
Remove the snap ring from the output shaft.
Remove the rotor and key.
247R200002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4 ×2).
Remove the snap ring from the output shaft.
Remove the speedometer sensor drive gear, and
ball.
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ISUZU KB P190 2007