2007 ISUZU KB P190 lock

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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ISUZU KB P190 2007

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

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).
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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

UNIT REPAIR (AW30–40LE) 7A4–13
10. Install the solenoid wiring.Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).
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249RY00012
11. Install a new oil strainer assembly with gaskets.
244RY00002
 Install the oil strainer with the gaskets to the valve
body. Tighten the four bolts.
Torque: 10 N ·m (1.0 kgf ·m/87 lb ·in)
244RY00003

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ISUZU KB P190 2007

7A4–26 UNIT REPAIR (AW30–40LE)
8. Install the snap ring.
248RY00014
9. While turning the sun gear input drum clockwise,install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.
248RY00020
10. Install the front planetary gear and bearing to the sun gear.
NOTE: Confirm the bearing and race is installed
correctly. Bearing and race diameter (Reference)
247RY00012With wooden blocks under the output shaft, stand
the transmission on the output shaft.
247RY00013
Inside Outside
Bearing 35.6 mm (1.40 in) 47.7 mm (1.88 in) Race 33.7 mm (1.33 in) 47.6 mm (1.87 in)

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–43
Disassembly
1. Check operation of one-way clutch.Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW37ASH004501
2. Remove OD direct clutch assembly from OD planetary gear assembly.
252L100004
3. Then remove thrust bearing with the race from ODdirect clutch drum. 4. Check piston stroke of OD direct clutch (C
–0).
Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
252L100005Use a dial indicator, measure the OD direct clutch
piston stroke applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)
252L100016

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ISUZU KB P190 2007

UNIT REPAIR (AW30–40LE) 7A4–51
16. Coat the assembled bearing and race withpetroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
252L100015
17. Align the flukes of discs in the direct clutch. Install the OD direct clutch assembly onto the OD
planetary gear.
252L100004
18. Check operation of one-way clutch Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
RUW37ASH004501
En dOFCallout
Inside diameter 28.9 mm (1.138 in)
Outside diameter 50.2 mm (1.976 in)
Legend (1) Free
(2) Lock

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ISUZU KB P190 2007

7A4–64 UNIT REPAIR (AW30–40LE)
Disassembly
Remove forward clutch assembly from direct clutch
assembly.
248RY00039
1. Place wooden blocks, etc. to prevent forward clutch shaft from touching the work stand, and place the
OD support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.
248RY00048
2. Check piston stroke of forward clutch (C –1).
248R200008Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing compressed
air (390 – 780 kPa or 57 – 114 psi) as shown.
Pack clearance: 0.6 – 1.0 mm (0.024 – 0.039 in)
3. Remove snap ring from clutch drum.
248RY00041
4. Remove the flange, disc and plate, and cushion plate.

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ISUZU KB P190 2007