ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-25
(21) 5th Block Ring (26) Reverse Gear
(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7B1-26 MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the bearing
snap ring.
2. Set the bearing remover 5-8840-2155-0 and the puller 5-8840-2027-0 to the bearing and the
mainshaft end, to remove the ball bearing.
262L100001
3. Remove the bearing snap ring, clip, speedometer
drive gear, retainer snap ring and the retainer.
4. Remove the thrust plate, thrust washer and lock ball.
5. Use a pair of snap ring pliers to remove the reverse idler gear snap ring.


226RS004

6. Remove the reverse idler gear assembly from the
intermediate plate.


226RS005
7. Remove the idle shaft pin, thrust washer, reverse idler gear, and reverse idler shaft.
8. Use a pair of snap ring pliers to remove the snap ring.
9. Attach a universal puller to the counter gear shaft. Use a universal puller to remove the ball bearing
and the counter 5th gear.


226RS006
10. Remove the counter reverse gear.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-27
11. Remove the 5th gear, 5th block ring, and needle
bearing (2 piece type).


226RS007
12. Remove the mainshaft nut according to following steps.
Attach the holding fixture 5-8840-2160-0 and the
base 5-8840-0003-0 to the mainshaft and the
counter gear.
226RW 212
• Engage the 3rd-4th synchronizer with the 3rd
gear.
• Engage the 1st-2nd synchronizer with the 1st
gear.

226RW 210
•
Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut.
226RW 211





BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7B1-28 MANUAL TRANSMISSION
13. Use screw drivers between the reverse gear and the
bearing plate to remove the Rev-5th synchronize
r
assembly, together with the reverse block ring and
reverse gear.


226RS010
14. Remove the needle bearing.
15. Use the torx bit wrench (T- 45) 5-8840-0047-0 to remove the bearing plate and screw from the
intermediate plate.

220RW 137
16. Use the snap ring pliers (1) to remove the mainshaft bearing snap ring (2).



226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate toward the rear of the
transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly. Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear, and then install it on
the base 5-8840-0003-0.
Install the intermediate plate on the gear assembly.
226RW 212



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-29
2. Install the bearing snap ring.
3.
Apply the recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install the bearing plate and screw.
Tighten the screws to the specified torque by using
torx bit wrench (T- 45) 5-8840-0047-0.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)

220RW 137
4. Install the needle bearing, reverse gear, and reverse block ring. 5. Assemble rev-5th synchronizer assembly b
y
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the oute
r
circumference.
2. Check that the inserts (3) fit snugly into the clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.


226RS013

226RS049


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7B1-30 MANUAL TRANSMISSION
6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).


226RS015
This will prevent the mainshaft from turning.
7. Install the new mainshaft hub nut. Use the mainshaft nut wrench 5-8840-2156-0 to
tighten the mainshaft nut to the specified torque.
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)
226RW 214


8. Use a punch to stake the mainshaft nut.


226RW 153
9. Install the needle bearing, 5th block ring, and 5th gear.
10.
Apply engine oil to the counter reverse gear and the
reverse gear.
Install the counter reverse gear to the counter shaft.
The reverse gear projection must be facing the
intermediate plate.


226RW 151




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-31
11. Install the counter 5th gear to the counter shaft.


226RS019
12. Install the ball bearing and bearing snap ring by
performing the following steps:
• Select the snap ring which will provide the
minimum clearance between the ball bearing
and the snap ring.


226RS020

• There are six snap ring sizes available.
The snap rings are color‐coded to indicate
their thickness.


226RS021
Ball Bearing and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
Snap Ring Availability
Thickness Color Coding
1.1 mm (0.043 in) W hite
1.2 mm (0.047 in) Yellow
1.3 mm (0.051 in) Blue
1.4 mm (0.055 in) Pink
1.5 mm (0.059 in) Green
1.6 mm (0.063 in) Brown
• Use a pair of snap ring pliers to install the snap
ring to the counter gear shaft.
The snap ring must be fully inserted into the
counter gear shaft snap ring groove.
13.
Assemble the reverse idler shaft, reverse idler gear,
thrust washer, and idle shaft pin into the reverse
idler gear assembly.
The thrust washer should be assembled with the oil
groove faces to gear side.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7B1-32 MANUAL TRANSMISSION
14. Select the reverse idler gear snap ring which will
provide the minimum clearance between the
intermediate plate and the snap ring.


226RS022
• There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
Snap Ring Availability
Thickness Color Coding
1.2 mm (0.047 in) W hite
1.3 mm (0.051 in) Yellow
1.4 mm (0.055 in) Blue

226RS021

• Use a pair of snap ring pliers to install the snap
ring to the reverse idler shaft.
The snap ring must be fully inserted into the
reverse idler shaft snap ring groove.
15. Install the thrust washer and lock ball by performing the following steps:
• Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in)
• Measure clearance "A" as shown in the figure.


226RS023
• Select an appropriate thrust washer from the
chart.
• There are four thrust washer sizes available.
Thrust Washer Availability
Thickness mm (in) Color
Coding A mm (in) Clearance
mm (in)
7.9 (0.311) W hite 8.05 - 8.1
(0.317-0.319) 0.15 - 0.25
(0.006-0.010)
8.0 (0.315) Yellow 8.1 - 8.2
(0.319-0.323) 0.1 - 0.25
(0.004-0.010)
8.1 (0.319) Green 8.2 - 8.3
(0.323-0.327) 0.1 - 0.25
(0.004-0.010)
8.2 (0.323) Blue 8.3 - 8.36
(0.327-0.329) 0.1 - 0.21
(0.004-0.008)
• The thrust washers are color-coded to indicate
their thickness, as shown in the figure.





BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-33

226RS024
• Apply grease to the thrust washer and the lock
ball.
• Install the thrust washer and the lock ball.
16. Install the thrust plate and retainer.
17. Install the retainer snap ring, clip, speedometer drive gear and bearing snap ring.
18.
Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
19. Install the bearing snap ring.




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7B1-34 MANUAL TRANSMISSION
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View


226RS026

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007