ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-65
16. Remove the engine rear mount bolts fixing
transmission.
220R300009
17. Remove the middle part of the transmissioncrossmember by removing the four fixing bolts and
nuts.
501R30007
18. Take out the rear support rubber. 19. Remove the starter. (Diesel engine only)
060L100070
20. Remove the transmission retaining nuts and bolts.
Remove the transmission assembly from the
vehicle.
21. Remove the transmission–transfer fixing bolts and nut, and disassemble the transfer from the
transmission.



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ISUZU KB P190 2007

7B1-66 MANUAL TRANSMISSION
Installation
1. Apply grease (BESCO L2 or equivalent) on the
splined portion of the output shaft.
2. Connect the transfer to the transmission.
3. Install the transmission-transfer bolts and nut and tighten them to the specified torque.
Torque: 41 N ⋅
⋅⋅
⋅
m (4.2 kgf ⋅
⋅⋅
⋅
m/30 lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BMF001501

4. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
5. 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.
6.
Align the top gear shaft with the clutch driven plate
spline.
7. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts, as shown in
the figure.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-67
Diesel engine
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)


RTW 77BLF004001

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ISUZU KB P190 2007

7B1-68 MANUAL TRANSMISSION
C24SE
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BLF004101

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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-69
8. Install the starter. (Diesel engine)
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)
9. Install the rear support rubber on the transmission and tighten the bolts to the specified torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
10. Install the middle part of transmission crossmember and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
11. Install the engine rear mount nuts.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from the
transmission side.
12. Apply grease to 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)
13. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe 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-2
14. Connect the transmission harness connectors and
clips. Connector: transfer neutral switch, 2W D -
4W D switch, actuator, car speed sensor, backup
switch, transmission neutral switch.
810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Backup 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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ISUZU KB P190 2007

7B1-70 MANUAL TRANSMISSION
15. 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
16. Install the front propeller shaft.
Refer to the section “Front Propeller Shaft”.
17. Install the rear propeller shaft.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
18. Install the center bearing on crossmember.
Torque: 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅
⋅⋅
⋅
m/51 lb ⋅
⋅⋅
⋅
ft)
19. Install the gear control lever.
Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
20. Install the grommet assembly.
Torque: Screw 1.4 N ⋅
⋅⋅
⋅
m (0.14 kgf ⋅
⋅⋅
⋅
m/12 lb ⋅
⋅⋅
⋅
in)
Nut 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)





RTW 47BMH000101
Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front
21. Install the front floor console and rear floor console.
22. Install the gear control lever knob. To the female thread portion, apply 3 - 4 drops o
f
adhesive (TB1344 or LOCTITE 222 or equiv.) and
tighten the transmission knob.
Torque: 9 N ⋅
⋅⋅
⋅
m (0.9 kgf ⋅
⋅⋅
⋅
m/78 lb ⋅
⋅⋅
⋅
in)
After tightening to specified torque, rewrench the
knob until the direction of the shift pattern is in the
due position.
23. Connect the battery ground cable.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-71
Transmission Case
Major Component






RTW 77BLF003701

Legend
(1) Gear Control Box Assembly and Gasket (7) Counter Front Bearing Snap Ring
(2) Rear Case Assembly (8) Front Cover (with Oil Seal)
(3) Intermediate Plate with Gear Assembly (9) Top Gear Bearing Snap Ring
(4) Transmission Case (10) Release Bearing: C24SE
(5) Release Bearing (with Spring): Diesel engine (11) Shift Fork: C24SE
(6) Shift Fork and Cover: Diesel engine



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ISUZU KB P190 2007

7B1-72 MANUAL TRANSMISSION
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case and drain the lubricant.
3. Remove the clutch release bearing with spring from the transmission case.
4. Remove the shift fork, and boot.
5. Remove the front cover and gasket from the transmission case.
6. Remove the snap ring fixing counter front bearing.
7. Use a pair of snap ring pliers to remove the snap ring fixing top gear bearing.


226RS001
8. Remove the gear control box assembly.
9. Remove the rear case assembly from the transmission case and intermediate plate.
10. Remove the intermediate plate with gear assembl
y
from the transmission case.

Rear Oil Seal Replacement
220R300025

Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard the used oil seal.
2. Apply engine oil to the new oil seal outer surfaces.
3.
Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 5- 8840-0007-0 to install the oil seal to the rear case.
Reassembly
1. Apply recommended liquid gasket (Three Bond TB1215) or its equivalent to the transmission case,
intermediate plate and rear case fitting surfaces.
2. Install the intermediate plate with gear assembly to the transmission case.
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal on the intermediate plate, with gear, by performing the following steps.
• Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
• Tighten the transmission rear case bolts and
nuts to the specified torque.
Torque: 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-73
mm (in)



RTW 77BSH008601

Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
4. Install a new gasket and gear control box assembly. Install the harness clips and brackets and then
tighten the four new gear control box bolts to the
specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
261R300004
5. Install the top gear bearing snap ring and counte
r
front bearing snap ring.
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to the outer circumference o
f
new oil seal.
• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R300002
7. Install a new gasket and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
Tighten the six front cover bolts to the specified
torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.6 kgf ⋅
⋅⋅
⋅
m/19 lb ⋅
⋅⋅
⋅
ft)


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7B1-74 MANUAL TRANSMISSION
8. Apply molybdenum disulfide type grease to the
areas shown in the figure and install the shift fork.
F07L100026
9. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease, as shown in the figure.
A07RW 075
10. Install the release bearing on the front cover, joining it to the shift fork.


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ISUZU KB P190 2007