Page 4505 of 6020
7A4-28 UNIT REPAIR (JR405E)
OIL PUMP ASSEMBLY
01PUMP32
Legend
1. Oil seal
2. O-ring (small)
3. Oil pump housing
4. Inner rotor
5. Outer rotor
6. Oil pump cover
7. O-ring (large)
8. Seal ring (large)
9. Seal ring (small)
10. Bearing race
02PUMP07
Disassembly steps
1. Oil pump cover
2. Oil pump housing • Loosen the 8 bolts evenly a little at a time.
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ISUZU KB P190 2007
Page 4506 of 6020
UNIT REPAIR (JR405E) 7A4-29
04PUMP10
•
Separate the oil pump cover from the oil pump housing
by tapping on each of the bolts with a plastic hammer.
06PUMP13
3. Inner rotor
Remove the inner rotor from the oil pump housing.
07PUMP14
4. Outer rotor
Remove the outer rotor from the oil pump housing.
15PUMP18
5. O-ring (small)
Remove the O-ring (small) from the oil pump housing.
08PUMP09
6. O-ring (large)
Remove the O-ring (large) from the oil pump cover.
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ISUZU KB P190 2007
Page 4507 of 6020

7A4-30 UNIT REPAIR (JR405E)
09PUMP05
7. Seal ring
Remove the 4 seal rings from the oil pump cover.
11PUMP43
Inspection
Oil pump cover
• Install new seal rings to the oil pump cover.
NOTE:
The seal ring with the large inside diameter fits into the
primary mating surface of the cover.
• Measure the gap between the seal ring and the seal ring
groove.
If the measured gap is outside the specified range, the
oil pump cover must be replaced.
Seal ring and seal ring groove gap: 0.10 ∼
∼∼
∼
0.25 mm
(0.0039 ∼
∼∼
∼
0.0098 in)
12PUMP45
Inner rotor
• Install the inner rotor to the oil pump housing.
• Use a straight edge to measure the side clearance
between the oil pump housing and the inner rotor.
If the measured clearance is outside the specified range,
the inner rotor must be replaced.
Oil pump housing and inner rotor side clearance:
0.02~0.04 mm (0.0008~0.0016 in)
13PUMP46
Outer rotor
• Install the outer rotor to the oil pump housing.
• Measure the gap between the outer rotor and the
crescent.
If the measured gap is outside the specified range, the
outer rotor must be replaced.
Outer rotor and crescent gap:
0.02~0.15 mm (0.0008~0.0059 in)
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ISUZU KB P190 2007
Page 4508 of 6020
UNIT REPAIR (JR405E) 7A4-31
Reassembly steps
15PUMP18
1. O-ring (small)
Install new O-ring (small) to the oil pump housing.
16PUMP29
2. Outer rotor
3. Inner rotor Install the outer rotor and the inner rotor to the oil pump
housing.
17PUMP42
NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.
18PUMP07
4. Oil pump cover
5. Oil pump housing Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
Torque: 9 N ⋅
⋅⋅
⋅
m (0.9 kgf ⋅
⋅⋅
⋅
m/78 Ib ⋅
⋅⋅
⋅
in)
6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring Install the 4 seal rings to the oil pump cover.
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ISUZU KB P190 2007
Page 4509 of 6020
7A4-32 UNIT REPAIR (JR405E)
CLUTCH PACK (REVERSE AND
HIGH CLUTCH ASSEMBLY)
01R&H17
Legend
1. Reverse and high clutch drum
2. Seal ring (reverse clutch)
3. Lip seal (reverse clutch)
4. Reverse clutch piston
5. Seal ring (small, high clutch)
6. Seal ring (large, high clutch)
7. High clutch piston
8. Return spring
9. High clutch cover
10. Snap ring
11. Dish plate (high clutch)
12. Driven plate (5, high clutch)
13. Drive plate (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plate (2, reverse clutch)
18. Drive plate (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)
02R&H18
Disassembly steps
1. Snap ring
Remove the reverse clutch snap ring.
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ISUZU KB P190 2007
Page 4510 of 6020
UNIT REPAIR (JR405E) 7A4-33
03R&H21
2. Retaining plate, drive plates, driven plates and dish
plate
Remove the reverse clutch retaining plate, the 2 drive
plates, the 2 driven plates, and the dish plate.
04R&H22
3. Snap ring
Remove the high clutch snap ring.
05R&H25
4. Retaining plate, drive plates, driven plates and dish
plate
Remove the high clutch retaining plate, the 5 drive plates,
the 5 driven plates, and the dish plate.
07R&H28
5. Snap ring
6. High clutch cover
7. Return spring • Install the spring compressor to the reverse and high
clutch drum.
Spring compressor: 5-8840-2767-0
• Carefully press the high clutch cover down.
Take care not to damage the return spring.
• Remove the snap ring.
• Remove the high clutch cover and the return spring.
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ISUZU KB P190 2007
Page 4511 of 6020
7A4-34 UNIT REPAIR (JR405E)
08R&H36
8. High clutch piston
9. Reverse clutch piston • Install the reverse and high clutch drum to the oil pump.
• Force compressed air into the oil pump oil channels.
• Remove the high clutch piston and the reverse clutch
piston.
09R&H37
12R&H39
10.Seal ring (high clutch)
Remove the 2 seal rings from the high clutch piston.
13R&H38
11.Seal ring (reverse clutch)
Remove the 2 seal rings from the reverse clutch piston.
Inspection
Drive plates
• Measure the drive plate facing thickness at 3 points.
• Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard – 2.0 mm (0.079 in)
Limit – 1.8 mm (0.071 in)
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ISUZU KB P190 2007
Page 4512 of 6020

UNIT REPAIR (JR405E) 7A4-35
Return springs • Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2
• Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)
10R&H40
Reverse clutch piston
• Apply compressed air (390 kPa/4.0 kgf/cm
2/57 psi) to
the reverse clutch piston from the outside to the inside.
The flow of air should be blocked.
11R&H44
•
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.
12R&H39
Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.
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ISUZU KB P190 2007