sensor ISUZU KB P190 2007 Workshop Repair Manual

7A4-82 UNIT REPAIR (JR405E)
Torque: 6 N⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 lb ⋅
⋅⋅
⋅
in)
• Remove the holding fixture from the transmission case.



RTW 47ASH001001

23.Speed sensor and turbine sensor
• Apply ATF to the new O-rings and install them in the
speed sensor (2) and the turbine sensor (3).
• Install the speed sensor and the turbine sensor. Tighten
the bolt to the specified torque.
Torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 Ib ⋅
⋅⋅
⋅
in)
24.Torque converter • Pour the new ATF into the torque converter.
• Shake the torque converter to thoroughly clean the
inside.
• Drain the ATF from the torque converter.
• Pour the new ATF into the torque converter.
NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.


RTW 47ASH000901

•
Install the torque converter.
• Measure the torque converter end play (A).
If the measured value is greater than the specified
minimum, the torque converter is correctly installed.
Torque converter end pay (Minimum): 67 mm (2.64
in)


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ISUZU KB P190 2007

7B-8 MSG MODEL


Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.




Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation procedure.
2. Remove the 2nd propeller shaft flange yoke nuts at the drive pinion side
1.
3. Remove the center bearing retainer bolts
2 .
4. Remove the 1st propeller shaft with the center bearing and the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle until the spline yoke is free of the transmission main shaft.



Harness Connector
Disconnect the back up light switch connector and the
speedometer sensor connector.




Slave Cylinder
Remove the slave cylinder from the transmission case.


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ISUZU KB P190 2007

MSG MODEL 7B-13




Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Torque N⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0 / 58)




Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque N ⋅m (kgf ⋅m/lb ⋅ft
)
78 (8.0 / 58)

Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.




Rear Propeller Shaft (Dual Shaft Type)
1. Place the center bearing and retainer 1 together with the
1st propeller shaft
2 and 2nd propeller shaft 7on the No.4
crossmember
3.
2. Insert the splined yoke
4 into the transmission main shaft
spline
5.
3. Tighten the center bearing retainer bolts
6 to the specified
torque.
Center Bearing Retainer Bolt Torque N ⋅m (kgf ⋅m/lb ⋅ft)
61 (6.2 / 45)



4. Connect the 2nd propeller shaft
7 and drive pinion side 8.
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
M8 : 35 (3.6 / 26)
M10 : 63 (6.4 / 46)




Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the 2nd
exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.


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ISUZU KB P190 2007

MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS





RTW 47BLF000301

Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly

6. Front cover with oil seal



7. Counter gear snap ring

8. Bearing snap ring
9. Rear cover with oil seal
10. Transmission case
11. Intermediate plate with gear assembly



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ISUZU KB P190 2007

7B-40 MSG MODEL
MAJOR COMPONENTS









RTW 47BLF000401

Reassembly steps
1. Intermediate plate with gear assembly

2. Rear cover with oil seal

3. Transmission case

4. Bearing snap ring
5. Counter gear snap ring



6. Front cover with oil seal
7. Speedometer driven gear
8. Gear control box assembly
9. Speedometer sensor
10. Clutch shift fork
11. Clutch shift block and release bearing



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-9
6. Remove the gear control lever.
7. Raise and support the vehicle with suitable stands.
8. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.


401RS023
9. Loosen the front exhaust pipe fixing nuts at the engine side but do not remove them. (Diesel engine
only)





RTW 67BSH000101
10. Disconnect the harness connectors and clips on the
transmission.
• Neutral Switch
• Back up Switch
• Car Speed Sensor
11. Remove the fuel pipe bracket with pipes from the transmission.
Diesel engine
220R300012
Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly




C24SE
Scan-1

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ISUZU KB P190 2007

7B1-14 MANUAL TRANSMISSION
5. Install the starter. (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
6. Install the rear support rubber on the transmission and tighten the nuts to the specified torque.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
7. Install the middle part of the transmission crossmember and the bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
8. Install the engine rear mount nuts fixing on the transmission crossmember.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from transmission
side.
9. Apply grease to the top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
10. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
Nut 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly






C24SE
Scan-1
11. Connect the transmission harness connectors and
clip. Connector: neutral switch, car speed sensor,
and backup switch.
12. Tighten the exhaust pipe fixing nuts to the specified torque. (Diesel engine only)
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)





RTW 67BSH000101



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ISUZU KB P190 2007

7B1-16 MANUAL TRANSMISSION
Transmission Case
Major Component






RTW 77BLF003301
Legend
(1) Gear Control Box Assembly and Gasket (7) Shift Fork and Cover: Diesel engine
(2) Speedometer Sensor and Driven Gear (8) Counter Front Bearing Snap Ring
(3) Rear Cover Assembly (9) Front Cover (with Oil Seal)
(4) Intermediate Plate with Gear Assembly (10) Top Gear Bearing Snap Ring
(5) Transmission Case (11) Release Bearing: C24SE
(6) Release Bearing (with Spring) : Diesel engine (12) Shift Fork: C24SE



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-17
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case and drain the lubricant.
3. Remove the clutch release bearing with spring from the transmission case.
4. Remove the shift fork, and boot.
5. Remove the front cover and gasket from the transmission case.
6. Remove the snap ring fixing counter front bearing.
7. Use a pair of snap ring pliers to remove the snap ring fixing top gear bearing.


226RS001
8. Remove the speedometer sensor.
Remove the plate.
Remove the driven gear bushing and driven gear.
NOTE: Apply a reference mark to the driven gea
r
bushing before removal.
9. Remove the gear control box assembly.
10. Remove the rear cover assembly from the transmission case and intermediate plate.
11. Remove the intermediate plate with gear assembly from the transmission case.

Reassembly
1. Apply recommended liquid gasket (Three Bond
TB1215) or its equivalent to the transmission case,
intermediate plate and rear cover fitting surfaces.
2. Install the intermediate plate with the gear assembly to the transmission case.
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the main shaft to sudden shock o
r
stress.
3. Install the rear cover with an oil seal on the intermediate plate, with the gear, by performing the
following steps.
• Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip. • Tighten the transmission rear case bolts and
nuts to the specified torque.
Torque: 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BSH008601
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
• After cleaning the screw face of a removed or ne
w
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent, before
tightening.


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ISUZU KB P190 2007

7B1-18 MANUAL TRANSMISSION
4. Install a new gasket and gear control box assembly.
Install the harness clips and brackets and then
tighten four new gear control box bolts to the
specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
261R300004
5. Install the O-ring (3) to the speedometer driven gear
bushing (2).
Install the driven gear to the speedometer driven gear bushing (2).
6. Install the speedometer driven gear assembly to the transmission rear cover.
Install the plate (1) to the transmission rear cover.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
7. Install the speedometer sensor.
Torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kgf ⋅
⋅⋅
⋅
m/20 lb ⋅
⋅⋅
⋅
ft)



RTW 77BSH008501
8. Install top gear bearing snap ring and counter front
bearing snap ring.
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
9. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to a new oil seal, on the oute
r
circumference.
• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R3000020
10. Install a new gasket and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
Tighten the six front cover bolts to the specified
torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.6 kgf ⋅
⋅⋅
⋅
m/19 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007