ISUZU KB P190 2007 Workshop Repair Manual

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

MSG MODEL 7B-29
REASSEMBLY

MAJOR COMPONENT
INTERNAL PARTS


Reassembly steps
1. Top & main gear shaft assembly
2. Counter gear shaft assembly
3. Rev. and 5th gear assembly


4. Shift arm assembly & interlock pin
5. Detent assembly



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ISUZU KB P190 2007

7B-30 MSG MODEL
MINOR COMPONENTS

TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR


Reassembly Steps
1. Mainshaft

2. Needle bearing

3. 2nd gear
4. 2nd block ring

5. 1st-2nd synchronizer assembly
6. 1st block ring

7. Needle bearing collar

8. Needle bearing

9. 1st gear

10. 1st gear thrust washer

11. Mainshaft ball bearing

12. Needle bearing

13. 3rd gear


14. 3rd block ring

15. 3rd-4th synchronizer assembly

16. Mainshaft snap ring
17. Needle bearing
18. 4th block ring

19. Top gear shaft

20. Ball bearing
21. Top gear shaft snap ring
22. Counter gear
23. Front ball bearing
24. Bearing snap ring

25. Rear ball bearing



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ISUZU KB P190 2007

MSG MODEL 7B-31




Important Operations
2. Needle Bearing
3. 2nd Gear
1) Apply the engine oil to the 2nd needle bearing and the 2nd gear.
2) Install the needle bearing and the 2nd gear to the mainshaft.
The dog teeth of the 2nd gear must be facing the rear side of the transmission.


5. 1st-2nd Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The outside sleeve heavy chamfering must be facing the rear of the transmission.
1 Chamfer Angle = 30 °
2 Chamfer Angle = 45 °



7. Needle Bearing Collar
Use a bench press and a collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)



8. Needle Bearing
9. 1st Gear
1) Apply the engine oil to the 1st needle bearing and the 1st
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 1st gear must be facing the front side of the transmission.


10. 1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the 1st gear side.


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ISUZU KB P190 2007

7B-32 MSG MODEL




11. Mainshaft Ball Bearing
1) Apply the engine oil to the ball bearing inside circumference.
2) Use a bench press and a bearing installer to install the bearing.
The bearing snap ring groove must be facing the front o
f
the transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)





12. Needle Bearing
13. 3rd Gear
1) Apply the engine oil to the 3rd needle bearing and the 3rd
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 3rd gear must be facing the front side of the transmission.






15. 3rd-4th Synchronizer Assembly
1)
Apply the recommended lubricating oil to the clutch hub
spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve light chamfering
1 and the clutch hub heavy
boss
2 must be facing the rear of the transmission.




16. Mainshaft Snap Ring
1) Select the snap ring which will provide the minimum clearance between the mainshaft and the snap ring.
There are four snap ring sizes available.
The snap rings are numbered to indicate their thickness.
Mainshaft and Snap Ring Clearance mm(in)
Standard
0 - 0.05 (0 - 0.002)


Snap Ring Availability
mm(in)
Thickness Identification Number
1.50 (0.059) 1
1.55 (0.061)2
1.60 (0.063)3
1.65 (0.065)4
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.

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ISUZU KB P190 2007

MSG MODEL 7B-33



19. Top Gear Shaft
20. Ball Bearing
Use a bench press and a installer to install the ball bearing to
the top gear shaft.
The snap ring groove must be facing the front of the
transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)




25. Rear Ball Bearing
Use a bench press and a bearing installer to install the bearing
to the counter gear.
Bearing Installer : 5-8840-0015-0 (J-22912-01)



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ISUZU KB P190 2007

7B-34 MSG MODEL
REVERSE GEAR AND 5TH GEAR



Reassembly Steps

1. Intermediate plate

2. Reverse idler shaft
3. Bearing snap ring
4. Bearing snap ring
5. Thrust washer

6. Reverse idler gear
7. Thrust washer

8. Counter reverse gear lock nut

9. Thrust washer
10. Needle bearing collar
11. Needle bearing
12. Reverse gear

13. Rev.-5th synchronizer assembly

14. Mainshaft lock nut and washer


15. Needle bearing
16. 5th block ring
17. 5th gear

18. Thrust washer and lock ball
19. Counter reverse gear
20. Counter 5th gear
21. Counter end ball bearing

22. Counter reverse gear nut and washer

23. Thrust washer thrust ring

24. Thrust ring snap ring
25. Mainshaft end ball bearing
26. Bearing spacer
27. Speedometer drive gear and lock ball
28. Bearing snap ring




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ISUZU KB P190 2007

MSG MODEL 7B-35


Important Operations
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
19 (1.9 / 14)




3) Set the mainshaft with gear assembly

1 and the counter
gear assembly
2 to a holding fixture
3.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the counte
r
shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the counter gear ball bearings.




6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
108 (11 / 80)



9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse gear side.


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ISUZU KB P190 2007

7B-36 MSG MODEL


13. Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer
1 and the insert short side 2
must be facing to the rear side of the transmission.



14. Mainshaft Lock Nut and Washer
1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use a lock nut wrench to tighten the lock nut to the specified torque.
Lock Nut W rench : 5-8840-0353-0 (J-36629)
Lock Nut Torque N⋅m(kgf ⋅m/lb ⋅ft)
127 (11 / 94)



22. Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque N⋅m(kgf ⋅m/lb ⋅ft)
108 (11 / 80)



18. Thrust Washer and Lock Ball
23. Thrust Washer Thrust Ring
24. Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.


3) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust W asher Clearance mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.


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ISUZU KB P190 2007