ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-5
Rear Oil Seal
Disassembled View
220R300030
Legend
(1) Rear Propeller Shaft (2) Rear Oil Seal

Removal
1. Raise and support the vehicle with suitable jack
stands.
2. Remove the propeller shaft flange yoke bolts and nuts at the differential side.
3. Remove center bearing from the crossmember.
4. Remove prepeller shaft from the transmission main shaft spline.
Refer to the section “Rear Propeller Shaft”.
5. Use a screwdriver to pry the rear oil seal from the rear cover.

Installation
1. Install a new oil seal using the installer 5-8522-0050- 0.



220RS044
2. Insert the splined yoke into the transimission
mainshaft spline.
3. Install the propeller shaft flange yoke to the drive pinion flange.

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ISUZU KB P190 2007

7B1-6 MANUAL TRANSMISSION
Torque : 63 N⋅
⋅⋅
⋅
m (6.4 kgf ⋅
⋅⋅
⋅
m/46 lb ⋅
⋅⋅
⋅
ft)
4. Install center bearing on crossmember.
Torque : 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅
⋅⋅
⋅
m/51 lb ⋅
⋅⋅
⋅
ft)
5. Check transmission fluid level.
6. Lower the vehicle.




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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-7
Transmission (4×
××
×
2)
Disassembled View



RTW 77BLF003201
Legend
(1) Gear Control Lever Knob (9) Slave Cylinder
(2) Rear Floor Console (bucket seat) (10) Nut: rear mount to Crossmember
(3) Front Floor Console (11) Transmission Crossmember
(4) Grommet Assembly (12) Nut: rear mount to transmission
(5) Gear Control Lever (13) Rear Mount Rubber
(6) Rear Propeller Shaft (14) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (15) Transmission Retaining Nut and Bolt
(8) Fuel Pipe Bracket (16) Transmission Assembly




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ISUZU KB P190 2007

7B1-8 MANUAL TRANSMISSION
Removal
1. Disconnect the battery ground cable.
2. Remove the gear control lever knob.
3. Remove the rear floor console. (Bucket seat)
Refer to the section “Floor Console”.
4. Remove the front floor console.
Refer to the section “Floor Console”.
745R300006
Legend
(1) Knob
(2) Rear Floor Console
(3) Front Floor Console

5. Remove the grommet assembly.




RTW 47BMH000101
Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front




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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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7B1-10 MANUAL TRANSMISSION
12. Remove slave cylinder and put it aside.
Diesel engine
220LV019
13. Support the transmission with a transmission jack.
220RS001
14. Remove engine rear mount nuts fixing on cross
member, from the transmission crossmember.
15. Remove engine rear mount nuts fixing on the
transmission.
220R300029
Legend
(1) Transmission
(2) Nut: rear mount to transmission
(3) Rear Mount Rubber
(4) Nut: rear mount to crossmember
(5) Transmission Crossmember
16. Remove the middle part of the transmission crossmember by removing four fixing bolts and nuts.
501R300008


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-11
17. Take out the rear mount rubber.
18. Remove the starter (Diesel engine only).
060L100070
19. Remove transmission retaining nuts and bolts. Remove the transmission assembly from the
vehicle.

Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of the transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must be the same.
3.
Align the top gear shaft spline with the clutch driven
plate spline.
4. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts as shown in
the figure.



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7B1-12 MANUAL TRANSMISSION
Diesel engine
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)


RTW 77BLF004001

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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-13
C24SE
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BLF004101

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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