Isuzu KB P190. Manual - part 1049

UNIT REPAIR (AW30–40LE)

7A4–61

5. Install four plates and four discs.

Install in order : P–D–P–D–P–D–P–D
P : Plate, D : Disc

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6. Install the flange, with the flat side facing downward.

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7. Install the snap ring with a screwdriver. 

Be sure the end gap of the snap ring is not aligned
with the cutout portion of the direct clutch drum.

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8. Check piston stroke of direct clutch (C–2).

Place the direct clutch assembly onto the OD
support assembly.

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Using a dial indicator, measure the direct clutch
piston stroke by applying and releasing compressed
air (390 – 780 kPa or 57 – 114 psi) as shown.

Pack clearance: 0.5 – 0.8 mm (0.020 – 0.031 in)

If the piston stroke is not within specification,
replace the discs and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.

7A4–62

UNIT REPAIR (AW30–40LE)

Flange sizes

RUW37ASH004901

9. Coat the clutch drum thrust washer (plastic) with

petroleum jelly and install it onto the direct clutch.

NOTE:  Make sure that the lugs fit into the cutout
portions on the direct clutch.

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Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward
clutch assembly.
Check that the distance from the direct clutch end to
the forward clutch end is 71.2mm (2.803in).

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Flange thickness

Flange thickness

3.3mm (0.130in)

3.8mm (0.150in)

3.4mm (0.134in)

—

3.5mm (0.138in)

4.0mm (0.157in)

3.6mm (0.142in)

—

3.7mm (0.146in)

4.2mm (0.165in)

UNIT REPAIR (AW30–40LE)

7A4–63

Forward Clutch Asseembly (C-1)

Disassembled View

RTW77ALF001001

EndOFCallout

Legend

(1) Race
(2) Thrust bearing
(3) Oil seal ring
(4) Forward clutch drum
(5) O-ring
(6) Piston
(7) O-ring
(8) O-ring

(9) Piston return spring

(10) Snap ring
(11) Race
(12) Thrust bearing
(13) Snap ring
(14) Flange
(15) Plate and disc

Six plates and six discs

(16) Cushion plate

7A4–64

UNIT REPAIR (AW30–40LE)

Disassembly

Remove forward clutch assembly from direct clutch
assembly.

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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.

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2. Check piston stroke of forward clutch (C–1).

248R200008

Using 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.

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4. Remove the flange, disc and plate, and cushion

plate.