Page 4153 of 6020
7A4–18 UNIT REPAIR (AW30–40LE)
8. Remove one flange, four plates and four discs (B–
0).
246RY00026
9. Remove the thrust bearing and two races.
247RY00003
10. Using snap ring pliers, remove the snap ring.
246RY00002
11. Remove the OD support.
Remove two bolts fixing the overdrive suppor t
assembly to the transmission case.
252RY00004
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ISUZU KB P190 2007
Page 4154 of 6020
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.
252RY00006
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.
248RY00004
248RY00005
Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)
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ISUZU KB P190 2007
Page 4155 of 6020
7A4–20 UNIT REPAIR (AW30–40LE)
14. Using snap ring pliers, remove the snap ring.
248RY00006
15. Applying compressed air to the oil hole, remove thesecond coast brake piston assembly.
248RY00007
16. Remove the direct clutch and forward clutch fromthe transmission case.
248RY00008
17. Remove the E-ring from the pin.Remove the pin from the brake band.
248RY00009
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ISUZU KB P190 2007
Page 4156 of 6020
UNIT REPAIR (AW30–40LE) 7A4–21
18. Remove the second coast brake band from thetransmission case.
248RY00010
19. Remove the front planetary ring gear from thetransmission case.
247RY00004
20. Remove the bearing and race.
247RY00005
21. Remove the race.
247RY00006
22. Using snap ring pliers, remove the snap ring.
248RY00011
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ISUZU KB P190 2007
Page 4157 of 6020
7A4–22 UNIT REPAIR (AW30–40LE)
NOTE: Hold the output shaft to prevent it from falling.
The output shaft falls when the snap ring is removed.
23. Remove the front planetary gear from the transmission case.
247RY00007
24. Remove sun gear input drum and one-way clutch.
248RY00012
25. Using two screwdrivers, remove the snap ring.
248RY00014
26. Remove, five discs and six plates (B –2).
248RY00015
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ISUZU KB P190 2007
Page 4158 of 6020
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.
248RY00016
28. Using snap ring pliers, remove the snap ring.
248RY00017
29. Remove the rear planetary gear, second brake drum and output shaft as an assembly.
247R200001
30. Remove the assembled thrust bearing and racefrom the transmission case.
248RY00018
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ISUZU KB P190 2007
Page 4159 of 6020
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.
247RY00009
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.
247RY00010
3. Using snap ring pliers, install the snap ring.
246RY00003
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
Page 4160 of 6020
UNIT REPAIR (AW30–40LE) 7A4–25
4. Check pack clearance of first and reverse brake.Using a thickness 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 in)
If the values are nonstandard, check for an improper
installation.
248RY00016
5. Install second brake piston sleeve.
246RY00004
6. Install one-way clutch in the transmission case.
247RY00011
7. Install discs and plates (B –2).
Instal the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)
246RY00005
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ISUZU KB P190 2007