indicator ISUZU KB P190 2007 Workshop Repair Manual

7A3-10 ON-VEHICLE SERVICE (JR405E)
SELECT LEVER



RTW 77ALF000201
Legend
1. Rear console
2. Front console
3. Shift lock release button
4. Shift lock button spring 5. Upper housing
6. Interlock controller
7. Base plate
8. Position indicator housing

9. Spring plate
10. Lamp assembly
11. Grooved pin
12. Shift lock unit
13. Lever assembly
14. Sleeve
15. Select lever knob



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ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-11
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Remove the rear console and the front console.
4. Remove the 2 screws fixing the select lever knob.
5. Remove the knob together with the knob button and spring from the lever.
6. Turn the sleeve counterclockwise to remove it. Make a note of the number of turns required to free
the sleeve.
7. Remove the harness connectors from the base plate.
8. Remove the upper housing (held in place by 4 latched fasteners).
9. Remove the lamp assembly by turning it counterclockwise.
10. Remove the spring plate.
11. Remove the grooved pin.
12. Disconnect the shift cable from the select lever.
13. Remove the lever assembly by pressing the rod down (lever in N position).
14. Remove the harness connectors from the shift lock unit, then remove the shift lock unit.
15. Remove the interlock controller.
16. If the replacement of shift lock release button o
r
shift lock button spring is required, remove the
position indicator housing, the shift lock button
spring and shift lock release button can be
removed.


Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.


RTW 77ALH000201
1. Install the interlock controller.
2. Install the shift lock unit and connect the harness to the shift lock unit.
3. Install the lever assembly to the base plate. a. Insert and secure the shaft and connect the cable.
b. Insert pawled end of the shaft into the base plate hole.
c. Insert the detent pin of the shaft into detent aperture (lever assembly in N position).
d. Install the grooved pin.



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ISUZU KB P190 2007

7B-26 MSG MODEL




BLOCK RING AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance mm(in)
StandardLimit
1st,2nd 3.46-3.74 (0.136-0.147)
3rd, 4th, 5th 3.51-3.79 (0.138-0.149)4.0 (0.157)





CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance mm(in)
Standard Limit
0.01 - 0.19 (0.0004 - 0.0075) 0.3 (0.012)



MAINSHAFT RUN - OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.
Mainshaft Run - Out mm(in)
Limit
Less than 0.03 (0.0012)





GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter mm(in)
Standard Limit
1st
Rev. 45.00-45.01
(1.7717-1.7720) 45.10 (1.7756)
2nd
3rd 41.00-41.01
(1.6142-1.6146) 41.10 (1.6181)
5th34.03-34.04
(1.3398-1.3402) 34.10 (1.3425)


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ISUZU KB P190 2007

MSG MODEL 7B-27




REVERSE IDLER GEAR AND IDLER
GEAR SHAFT CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to measure the idler gear inside diameter.
3. Calculate the idler gear and idler gear shaft clearance.
Idler gear inside diameter - idler gear shaft diameter = idle
r
gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the idle
r
gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance mm(in)
Standard Limit
0.041 - 0.074 (0.0016 - 0.0029) 0.150 (0.0059)





CLUTCH HUB SPLINE PLAY
1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
It the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch Hub Spline Play mm(in
)

Standard Limit
0 - 0.019 (0 - 0.0075) 0.20 (0.0079)


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ISUZU KB P190 2007

7B-28 MSG MODEL


BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play mm(in)
Limit
0.2 (0.0079)



FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.





Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer : 5-8840-0026-0 (J-26540)
2. Apply engine oil to the oil seal lip.



REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.





Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the rear cover.
Oil Seal Installer : 5-8522-0050-0 (J-29769)
2. Apply engine oil to the oil seal lip.



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ISUZU KB P190 2007

7B1-40 MANUAL TRANSMISSION
Mainshaft Run-out
• Install the mainshaft to V-blocks.
• Use a dial indicator to measure the mainshaft
central portion run-out.


226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter
• Use an inside dial indicator to measure the gear
inside diameter.


226RS040
If the measured value is less than the specified limit,
the gear must be replaced.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
• Use a micrometer to measure the idler gear shaft
diameter.
• Use an inside dial indicator to measure the idle
r
gear inside diameter.

226RS041
• Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-41
Clutch Hub Spline Play
• Set a dial indicator to the clutch hub which requires
measuring.


226RS042
• Move the clutch hub as far to the right and left as
possible.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd 3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
• Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)



226RS043

Reassembly
1. Install the center roller bearing to counter gear shaft.
•
Apply engine oil to the bearing inner and outer
circumferences.
• Install the roller bearing in the proper direction.
NOTE: Check that the outer race moves only in the
direction of the arrow.


226RS044
2. Install the front roller bearing by performing the following steps.
• Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gea
r
shaft.
• Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.



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ISUZU KB P190 2007

7B1-94 MANUAL TRANSMISSION
Mainshaft Run-out
• Install the mainshaft to V-blocks.
• Use a dial indicator to measure the mainshaft
central portion run-out.


226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter
• Use an inside dial indicator to measure the gear
inside diameter.


226RS040
If the measured value is less than the specified limit,
the gear must be replaced.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
• Use a micrometer to measure the idler gear shaft
diameter.
• Use an inside dial indicator to measure the idle
r
gear inside diameter.

226RS041
• Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-95
Clutch Hub Spline Play
• Set a dial indicator to the clutch hub which requires
measuring.


226RS042
• Move the clutch hub as far as possible to the right
and left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd 3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
• Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)





226RS043

Reassembly
1. Install the center roller bearing to the counter gear
shaft.
•
Apply engine oil to the bearing inner and outer
circumferences.
• Install the roller bearing in the proper direction.
NOTE: Check that the outer race moves only in the
direction of the arrow.


226RS044
2. Install the front roller bearing by performing the following steps.
• Use the bearing installer 5-8840-2194-0 to install
the front roller bearing inner race to the counte
r
gear shaft.
• Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.



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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-23
Block Ring and Insert Clearance
Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and insert.
If the measured value exceeds the specified limit, the
block ring and insert must be replaced.
Clutch Hub and Insert Clearance
Use a thickness gauge to measure the clearance
between the clutch hub and insert.
If the measured value exceeds the specified limit, the
clutch hub and insert must be replaced. Gear Inside Diameter
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit,
the gear must be replaced.
Standard
Limit
3rd - 4th 5th 3.59 - 3.91 mm
(0.141 - 0.154 in) 4.10 mm
(0.161 in)
LNW25CSH028401
RTW77BSH006501
Standard Limit
3rd - 4th 5th 0.09 - 0.31 mm
(0.004 - 0.012 in) 0.40 mm
(0.016 in)
Standard Limit
3rd 45.000 - 45.016 mm
(1.7717 - 1.7723 in) 45.056 mm
(1.7739 in)
5th 48.000 - 48.016 mm
(1.8898 - 1.8904 in) 48.056 mm
(1.8920 in)
LNW25CSH028701
LNW25CSH028901

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ISUZU KB P190 2007