ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-85
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.



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7B1-86 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.



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MANUAL TRANSMISSION 7B1-87

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. Apply engine oil to the bearing inner and oute
r
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
18.
Apply engine oil to the oil seal collar inner
circumference.
Install the oil seal collar to the mainshaft by using
the installer 5-8840-2159-0.
19. Install the oil seal collar snap ring.




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7B1-88 MANUAL TRANSMISSION
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassembled View


226RS026

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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-89
Legend
(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring
(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft



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ISUZU KB P190 2007

7B1-90 MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring.
2. Remove the top gear shaft with ball bearing.
3. Use a bench press and the bearing remover 5-8840- 0015-0 to remove the ball bearing.
226RW 216
4. Remove the needle bearing and top block ring,mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the mainshaft snap ring.


226RS008

6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronize
r
assembly as a set.
Disassemble the synchronizer assembly.
226RW 217
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove the 3rd block ring, 3rd gear, and needle bearing.
8. Use a bench press and the bearing remover 5-8840- 0015-0 to remove the 1st gear together with the
mainshaft ball bearing, 1st gear thrust bearing, and
the needle bearing collar.
226RW 218




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MANUAL TRANSMISSION 7B1-91
9.Disassemble the 1st inside ring, 1st outside ring, and
1st block ring.
10.Remove the needle bearing.
11.Use a pair of snap ring pliers to remove the clutch hub snap ring.


226RS031
12.Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 2nd gear together with 1st-2nd
synchronizer assembly, 2nd block ring, 2nd outside
ring, and inside ring.
Disassemble the synchronizer assembly.
226RW 220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
13. Remove the needle bearing from the mainshaft.
14. Remove the bearing snap ring.
15. Remove the front roller bearing by performing the following steps.
• Remove the ring, outer race and bearing
assembly by using a bench press and remove
r
5-8840-0015-0.
• Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RW 219
16. Remove the center roller bearing from the counter
gear shaft.




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7B1-92 MANUAL TRANSMISSION
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Block Ring and Dog Teeth Clearance
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS035
If the measured value exceeds the specified limit,
the block ring must be replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)



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MANUAL TRANSMISSION 7B1-93
1st-2nd Synchronizer (3-CONE)
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)
Block Ring and Insert Clearance
• Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.


226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.157 in)
1st-2nd 3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th 3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)

Clutch Hub and Insert Clearance
• Use a thickness gauge to measure the clearance
between the clutch hub and the insert.


226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance
Standard Limit
1st-2nd3rd-4th 0.01 – 0.21 mm
(0.0004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th 0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)



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7B1-94 MANUAL TRANSMISSION
Mainshaft Run-out
• Install the mainshaft to V-blocks.
• Use a dial indicator to measure the mainshaft
central portion run-out.


226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter
• Use an inside dial indicator to measure the gear
inside diameter.


226RS040
If the measured value is less than the specified limit,
the gear must be replaced.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
• Use a micrometer to measure the idler gear shaft
diameter.
• Use an inside dial indicator to measure the idle
r
gear inside diameter.

226RS041
• Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)


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