2007 ISUZU KB P190 brake

UNIT REPAIR (JR405E) 7A4-55
01L&R-CS05
Legend
1. Seal ring
2. Low one-way clutch inner race
3. Return spring
4. Low and reverse brake piston
5. Seal ring
6. Lip seal

7. Transmission case
8. Snap ring
9. Retaining plate
10. Driven plate
11. Drive plate
12. Dish plate



04CASE-AY52

Disassembly steps
1. Harness assembly
Remove the fixing bolt and the harness assembly.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-57

11CASE-AY01

5. Oil seal
Using a screwdriver, remove the oil seal from the
transmission case.




Inspection
2 – 4 brake drive plates
Measure the 2-4 brake drive plate facing thickness at 3
points and calculate the average value.
If the average value is less than the specified limit, the 2-4
brake drive plate must be replaced.
2 – 4 brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
Low and reverse brake drive plates
Measure the low and reverse brake drive plate facing
thickness at 3 points and calculate the average value.
If the average value is less than the specified limit, the lo
w
and reverse drive plate must be replaced.
Low and reverse brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
2 – 4 brake return springs
• Check the number of effective 2-4 brake return spring
coils.
Effective return spring coils (Standard): 10.2
• Measure the 2-4 brake return spring outside diameter,
free length, and linear diameter.
If any of the measured values exceed the specified limit,
the 2-4 brake return spring must be replaced.
2 – 4 brake return spring measurements (Standard):
Outside diameter = 6.9 mm (0.272 in)
Free length = 22.5 mm (0.886 in)
Linear diameter = 1.1 mm (0.043 in)
Low and reverse brake return springs
• Check the number of effective low and reverse brake
return spring coils.
Effective return spring coils (standard): 4.8
• Measure the low and reverse brake return spring outside
diameter, free length, and linear diameter.
If any of the measured values exceed the specified limit,
the low and reverse return spring must be replaced.
Low and reverse brake return spring measurements
(Standard):
Outside diameter = 11.2 mm (0.441 in)

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ISUZU KB P190 2007

7A4-60 UNIT REPAIR (JR405E)

26L&R01

6. Low and reverse brake piston
• Install new seal rings to the low and reverse piston.







RTW 47ASH000701
As shown in a figure, a sealing lip is attached.

27ASSY004

•
Install the low and reverse brake piston to the
transmission case.


28ASSY005

7. Return spring
• Install the return spring to the low and reverse brake
piston.


29ASSY006

8. Low one-way clutch inner race
• Install the low one-way clutch inner race to the
transmission case.
• Temporarily tighten the 7 fixing bolts.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-61

31ASSY074

•
Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-wa
y
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 N ⋅
⋅⋅
⋅
m (2.4 kgf ⋅
⋅⋅
⋅
m/17 Ib ⋅
⋅⋅
⋅
ft)


32ASSY007

9. Dish plate, driven plates, drive plates, and retaining
plate (low and reverse brake)
• Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.


33ASSY008



34ASSY009



35N-SPG02

•
Install the N-type spring.


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ISUZU KB P190 2007

7A4-62 UNIT REPAIR (JR405E)





RTW 37AMF0001-X



36ASSY10

•
Install the retaining plate (4).


37ASSY011

•
Install the snap ring.


38L&R03

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil passages of the transmission case to
check low and reverse brake operation.
If the low and reverse brake does not operate, check the
seal rings for damage and replace if necessary. Also
check that no parts have been installed out of place.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-63

39L&R04


249L300003

•
Measure the clearance between the low and reverse
retaining plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the prope
r
size (thickness).
Low and reverse retaining and snap ring clearance:
0.7~1.1 mm (0.028~0.043 in)
Available low and reverse brake retaining plate
thicknesses
5.2 mm (0.205 in)
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)

10.Dish plate, drive plates, driven plates, and retaining
plate. (2-4 brake)
NOTE:
Ensure the attachment direction of dish plate is correct.
If 2-4 brake clearance measurement is required, it must be
done now.
Brake clearance cannot be measured after the carrier
assembly has been installed.

402-4B08

•
Install the 2-4 brake dish plate to the transmission case
(plate contact surface).


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ISUZU KB P190 2007

7A4-64 UNIT REPAIR (JR405E)

412-4B09

•
Install the drive plates, driven plates, and the retaining
plate.


422-4B10



432-4B11



442-4B12

11.2 – 4 brake piston and 2 – 4 brake retainer
• Install new seal ring to the 2-4 brake piston.
• Install the 2-4 brake piston to the 2-4 brake retainer.


452-4B15

•
Install the 2-4 brake piston and the 2-4 brake retainer to
the transmission case.
Pay close attention to the retainer projection from the
case groove.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-65

472-4B17

•
Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Be sure that the spring compressor is perfectly centered
(an off-center special tool will damage the return spring).
• Use the spring compressor to force the 2-4 brake
retainer.


482-4B18

NOTE:
To avoid damaging the return spring, apply as little force
as possible to the 2-4 brake retainer.
• Install the snap ring.


492-4B22

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the oil passages of the transmission case to
operate and break-in the 2-4 brake.


502-4B19

•
Measure the clearance between the 2-4 brake retainer
and the retaining plate.
If the clearance is outside the specified range, replace
the existing brake retainer with a new one of the prope
r
size (thickness).
2 – 4 brake retainer and retaining plate clearance:
1.0~1.4 mm (0.039~0.055 in)
Available 2-4 brake retaining plate thicknesses
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
6.2 mm (0.244 in)
6.4 mm (0.252 in)
• Use the spring compressor to release the 2-4 brake.



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ISUZU KB P190 2007