Isuzu KB P190. Manual - part 1034

UNIT REPAIR (AW30–40LE)

7A4–1

SECTION 7A4

TABLE OF CONTENTS

UNIT REPAIR (AW30–40LE)

Major Components (1) ...................................

7A4–2

Major Components (1) and Associated

parts ...........................................................

7A4–2

Disassembly steps......................................

7A4–2

Components (1) .............................................

7A4–4

Reassembly ................................................

7A4–4

Major Components (2) ...................................

7A4–6

Major Componets (2) and Associated 

Parts...........................................................

7A4–6

Disassembly ...............................................

7A4–7

Reassembly ................................................

7A4–10

Major Components (3) ...................................

7A4–15

Major Components (3) and Associated

Parts...........................................................

7A4–15

Disassembly ...............................................

7A4–16

Reassembly ................................................

7A4–24

Diaassembly, Inspection and Reassembly

of minor Components.................................

7A4–36

Oil Pump ........................................................

7A4–37

Disassembly View ......................................

7A4–37

Disassembly ...............................................

7A4–37

Inspection and Repair.................................

7A4–38

Reassembly ................................................

7A4–40

OD Planetary Gear and OD Direct Clutch

Assembly (C–0)..........................................

7A4–42

Disassembled View ....................................

7A4–42

Disassembly ...............................................

7A4–43

Inspection and Repair.................................

7A4–46

Reassembly ................................................

7A4–47

OD Support Assembly ...................................

7A4–52

Disassembled View ....................................

7A4–52

Disassembly ...............................................

7A4–52

Inspection and Repair.................................

7A4–53

Reassembly ................................................

7A4–54

Direct Clutch Assembly (C-2) ........................

7A4–57

Disassembled View ....................................

7A4–57

Disassembly ...............................................

7A4–58

Inspection and Repair.................................

7A4–59

Reassembly ................................................

7A4–60

Forward Clutch Asseembly (C-1)...................

7A4–63

Disassembled View ....................................

7A4–63

Disassembly ...............................................

7A4–64

Inspection and Repair.................................

7A4–65

Reassembly ................................................

7A4–66

Front Planetary Gear .....................................

7A4–70

Disassembled View ....................................

7A4–70

Disassembly ...............................................

7A4–70

Inspection and Repair.................................

7A4–70

Reassembly ................................................

7A4–71

Planetary Sun Gear and No.1 One-Way 

Clutch .........................................................

7A4–72

Disassembled View ....................................

7A4–72

Disassembly ...............................................

7A4–73

Inspection and Repair.................................

7A4–73

Reassembly ................................................

7A4–74

Second Brake Assembly (B–2)......................

7A4–76

Disassembled View ....................................

7A4–76

Disassembly ...............................................

7A4–76

Inspection and Repair.................................

7A4–77

Reassembly ................................................

7A4–77

Rear Planetary Gear Assembly and Output 

Shaft...........................................................

7A4–80

Disassembled View ....................................

7A4–80

Disassembly ...............................................

7A4–81

Reassembly ................................................

7A4–83

First and Reverse Brake (B–3) ......................

7A4–86

Disassembled View ....................................

7A4–86

Disassembly ...............................................

7A4–87

Reassembly ................................................

7A4–88

Transmission Case ........................................

7A4–91

Disassembled View ....................................

7A4–91

Disassembly ...............................................

7A4–91

Reassembly ................................................

7A4–92

Torque Converter...........................................

7A4–94

Inspection and Repair.................................

7A4–94

Adapter Housing (4 

×

 4).................................

7A4–95

Disassembled View ....................................

7A4–95

Disassembly ...............................................

7A4–95

Reassembly ................................................

7A4–95

Extension Housing (4 

×

 2) .............................

7A4–96

Disassembled View ....................................

7A4–96

Disassembly ...............................................

7A4–96

Reassembly ................................................

7A4–97

Main Data and Specifications ........................

7A4–98

Special Tools ................................................. 7A4–102

7A4–2

UNIT REPAIR (AW30–40LE)

Major Components (1)

Major Components (1) and Associated parts

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Disassembly steps

1. Remove the torque converter.

2. Remove the select lever.

Legend

(1) Torque converter
(2) Neutral start switch
(3) Elbow
(4) Oil temperature sensor
(5) Breather hose

(6) Output revolution sensor
(7) Adapter housing
(8) Transmission assembly
(9) Select lever

(10) Input revolution sensor

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.

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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)

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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.

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5. Install the oil temperature sensor to the transmission

case.

Torque: 15 N·m (1.5 kgf·m/11 Ib·ft)

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