ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-55
3. WALKING OR JUMPING OUT OF GEAR

Checkpoint Trouble Cause Countermeasure

Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
W orn shift rod and/or sliding
faces
W orn detent ball
Detent springRepair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OK NG
NG
NG
NG
OK
OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust playReplace the worn partsW orn thrust washer, collar,
and/or gear thrust faces
Replace the worn partsW orn shift arm and/or
synchronizer sleeve groove
NG
NG
OKShift arm and synchronizer
sleeve


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ISUZU KB P190 2007

7B1-56 MANUAL TRANSMISSION
Checkpoint Trouble Cause Countermeasure

Synchronizer assembly
Bearings (Mainshaft,
countershaft, and individual
gears)
Replace the spring
Replace the bearing(s)
W eak or broken spring
W orn or broken bearings(s)
Mainshaft splines
Synchronizer clutch hub
splines
Replace the main shaft and
the synchronizer clutch hubW orn splines
OK NG
NG
NG
OK
OK
Continued from the previous page


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-57
4. OIL LEAKAGE

Checkpoint Trouble Cause Countermeasure

Gear oilReplace the gear oilImproper gear oil
Drain plug and/or filler plugTighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OK NG
NG
NG
OK
OKOil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
W orn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil sealReplace the oil seal
Replace the gasket(s)
W orn or scratched oil seal
Defective or improperly
installed gasket(s)
OK NG
NG
NG
NG
OK
OKGaskets



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7B1-58 MANUAL TRANSMISSION
Special Tools (4×
××
×
2)

ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2155-0
(J-37217)
Bearing remover 5-8840-2159-0
(J-37223)
Mainshaft end bearing installer
5-8840-2027-0
Puller 5-8840-0015-0
(J-22912-01) Bearing
remover/installer
5-8840-2160-0
(J-37224)
Holding fixture 5-8522-0050-0
(J-29769)
Rear case oil seal installer
5-8840-0003-0
(J-3289-20)
Holding fixture base 5-8840-0026-0
(J-26540)
Front cover oil seal installer
5-8840-2156-0
(J-37219)
Mainshaft nut wrench 9-8522-1165-0
(J-6133-01)
Mainshaft collar remover
5-8840-0047-0
(J-37225)
Tork bit wrench
(T– 45)
5-8840-2194-0
(J-35283)
Bearing installer


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-59
Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLE MENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNECESSARY SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require a
replacement after removal. ISUZU/GM will also call
out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.


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7B1-60 MANUAL TRANSMISSION
General Description
MUA5G/5H/5S Transmission (4×
××
×
4)
A07R300003
The MUA5G/5H/5S is a constant mesh transmission,
synchronized in all speeds. The transmission is
designed for a great reduction of the shift effort and the
quietest possible operation.
Principle parts of the transmission are the integral clutch
housing, the intermediate plate, the rear case, and the
gears.
The transmission control box is built into the
transmission.



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MANUAL TRANSMISSION 7B1-61
Transmission (4×
××
×
4)
Disassembled View



RTW 77BLF003601
Legend
(1) Gear Control Lever Knob (10) Transfer Assembly
(2) Rear Floor Console (bucket) (11) Fuel Pipe Bracket
(3) Front Floor Console (12) Slave Cylinder
(4) Grommet Assembly (13) Rear Mount Nut
(5) Gear Control Lever (14) Transmission Crossmember
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Front Propeller Shaft (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe Nut (Diesel engine) (17) Transmission Assembly
(9) Transmission-Transfer Fixing Bolt



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ISUZU KB P190 2007

7B1-62 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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MANUAL TRANSMISSION 7B1-63
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.
9. Remove the front propeller shaft.
NOTE:
Apply alignment marks on the flange at both
front and rear sides.
401RS023
10. Loosen the front exhaust pipe fixing nuts at the engine side but do not remove them. (Diesel engine
only)





RTW 67BSH000101
11. Disconnect the harness connectors and clips on the
transmission and transfer.
• Neutral Switch: Transmission
• Back up Switch
• Actuator
• 2W D-4W D Switch
• Neutral Switch: Transfer
• Car Speed Sensor

810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Back up Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W D - 4W D Switch Connector
(6) Neutral Switch Connector: Transfer


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7B1-64 MANUAL TRANSMISSION
12. Remove the fuel pipe brackets with pipes from the
transmission.
Diesel engine
220R300012
Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly





C24SE
Scan-2
13. Remove the slave cylinder and put it aside.
220LV019
14. Support the transmission with a transmission jack.
220RS0001
15. Remove the engine rear mount nuts from the
transmission crossmember.




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ISUZU KB P190 2007