2007 ISUZU KB P190 brake

UNIT REPAIR (JR405E) 7A4-71

03ASSY013

3. Carrier and low clutch assembly
Install the carrier and low clutch assembly to the
transmission case.
NOTE:
Do not allow the low clutch drum end to protrude beyond
the 2-4 brake plate contact surface (transmission case).


04ASSY014

4. Bearing
Install the bearing to the carrier and low clutch assembly.


05ASSY015

5. Driven plates, drive plates, retaining plate, and dish
plate (2 – 4 brake)
Install the 2-4 brake 5 driven plates (1), 5 drive plates (2),
retaining plate (3), and dish plate (4) in that order.
NOTE:
•
••
•
The thickest driven plate (5.6 mm) must be installed
at the bottom (transmission case plate surface).
•
••
•
The dish plate side with the identification mark must
face the retaining plate.


06ASSY016



07ASSY017



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ISUZU KB P190 2007

7A4-72 UNIT REPAIR (JR405E)

08ASSY018






RTW 47ASH000401



09U-SPG2

6. 2 – 4 brake spring
Install the three 2-4 brake springs to the transmission case.





248L300009



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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-73

10ASSY019

7. Return spring and 2 – 4 brake retainer
• Align the transmission case groove and the 2-4 brake
retainer projection.
• Install the return spring and the 2-4 brake retainer.

11ASSY028



12ASSY029
• Install the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
NOTE:
Carefully center the spring compressor to prevent damage
to the return spring.
• Push the 2-4 brake retainer into place.
NOTE:
Do not push the brake retainer too far.
Damage to the return spring will result.
• Install the snap ring.


14ASSY031



17ASSY113

8. Sleeve and seal ring
• Install the new sleeve and seal ring to the transmission
case.

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ISUZU KB P190 2007

7A4-74 UNIT REPAIR (JR405E)

192-4B22

•
Force compressed air (390 kPa/4.0 kgf/cm2/57 psi)
through the transmission case oil passage to 2-4 brake
operation.
If the 2-4 brake does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.


20ASSY037

9. Bearing race, front sun gear, and bearing
• Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.


21ASSY040
• Install the front sun gear to the transmission case.


22ASSY042
• Install the bearing to the front sun gear.


23ASSY045

10.High clutch hub and bearing race
Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-83
SERVICE STANDARD
Name BESCO ATF III ATF
Quantity L (US gal/Imp gal) 9.2 – 9.6 (2.43-2.54/2.02-2.11)
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plates / driven plates 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coils 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring Linear diameter mm (in) 1.2 (0.047)
Number of drive plates / driven plates 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coils 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring Linear diameter mm (in) 1.1 (0.043)
Number of drive plates / driven plates 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.024 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in) 5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plates / driven plates
6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)

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ISUZU KB P190 2007

7A4-84 UNIT REPAIR (JR405E)
SERVICE STANDARD (Cont’d)
Number of coils 4.8
Outside diameter mm (in) 11.2 (0.441)
Free length mm (in) 22.3 (0.878)
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drives / driven plates 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and retaining plate clearance mm (in) 1.0 – 1.4 (0.039 – 0.055)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
6.0 (0.236)
6.2 (0.244)
Available 2-4 brake retaining plate thickness mm (in)
6.4 (0.252)
Number of coils 10.2
Outside diameter mm (in) 6.9 (0.272)
Free length mm (in) 22.5 (0.886)
2-4 brake
Return spring Linear diameter mm (in) 1.1 (0.043)
Output shaft Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Total end play mm (in) 0.25 – 0.55 (0.0098 – 0.0217)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
2.2 (0.087)
Total end play
Available oil pump bearing race thickness mm (in)
2.4 (0.094)
Torque converter end play mm (in) 67.0 (2.638)


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-85
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME


5-8841-0841-0

Holding Fixture


5-8840-0003-0

Holding Fixture Base


5-8840-2764-0

2-4 Brake Spring Compressor


5-8840-2767-0

High Clutch Spring Compressor


5-8840-2759-0

Low Clutch Spring Compressor


5-8840-2761-0

Oil Pump Oil Seal Installer


5-8840-2769-0

Rear Extension Oil Seal Installer


5-8840-2770-0

Rear Adapter Oil Seal Installer


5-8840-2758-0

Manual Shaft Oil Seal Installer

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ISUZU KB P190 2007

CLUTCH 7C-21
AIR BLEEDING
Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.


1. Set the parking brake.
2. Top up reservoir with recommended brake fluid.



3. Connect a transparent vinyl tube to air bleeder valve.
4. Fully depress clutch pedal several times.


RUW 57CSH000201

5. W ith clutch pedal depressed, open bleeder valve to release
air.
6. Close bleeder valve.
7. Repeat steps 5 through 6 above until brake fluid flows from air bleeder valve without air bubbles.
8. Bleed air from clutch damper according to the above procedure.
9. Repeat the above bleeding procedure until the air completely removed.



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ISUZU KB P190 2007