ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-95
Clutch Hub Spline Play
• Set a dial indicator to the clutch hub which requires
measuring.


226RS042
• Move the clutch hub as far as possible to the right
and left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd 3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
• Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)





226RS043

Reassembly
1. Install the center roller bearing to the counter gear
shaft.
•
Apply engine oil to the bearing inner and outer
circumferences.
• Install the roller bearing in the proper direction.
NOTE: Check that the outer race moves only in the
direction of the arrow.


226RS044
2. Install the front roller bearing by performing the following steps.
• Use the bearing installer 5-8840-2194-0 to install
the front roller bearing inner race to the counte
r
gear shaft.
• Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.



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ISUZU KB P190 2007

7B1-96 MANUAL TRANSMISSION
• Use the bearing installer 5-8840-2194-0 to install
the ring.




RTW 57BSH000101
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install the bearing snap ring to the counter gear
shaft.
4.
Apply engine oil to the needle bearing and the 2nd
gear thrust surfaces.
Install the needle bearing and the 2nd gear to the
mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.


226RS046

5.
Assemble the 2nd inside ring, 2nd outside ring, and
the 2nd block ring.
•
Apply engine oil to the synchronizer ring friction
surfaces.


226RS047
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-97
6. Assemble the 1st-2nd synchronizer assembly by
performing the following steps:
1. Check that the inserts (3) fit snugly into the clutch hub (5) insert grooves.
2. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.




266RS049
7. Install the synchronizer assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.


226RS048
8. Install the clutch hub snap ring by performing the following steps:
• Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring.



226RS050
•
There are three snap ring sizes available.
• The snap rings are color coded to indicate thei
r
thickness as shown in the figure.


226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) W hite
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
• Use a pair of snap ring pliers to install the snap
ring to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.



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ISUZU KB P190 2007

7B1-98 MANUAL TRANSMISSION

226RS031
9. Install the needle bearing, 1st block ring, 1st outside
ring, 1st inside ring, and 1st gear.
•
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
• The 1st gear dog teeth must be facing the
transmission front side.


226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring

10. Install the 1st gear thrust bearing and the race to the
main shaft.
The thrust bearing side must be facing the
transmission front side.


226RS054
11. Apply engine oil to the mainshaft ball bearing and the mainshaft.
Install the ball bearing and needle bearing collar to
the mainshaft.
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.


226RS055



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-99
12. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing and the 3rd gear to the
mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.


226RS056
13. Install the 3rd block ring.
14. Check and install the 3rd-4th synchronizer assembl
y
by using the following steps:
1. Check that the inserts (3) fit snugly into the clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be facing the 3rd gear side.


226RS049

226RW 221
15. Select and install mainshaft snap ring using the
following instructions:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.


226RS058
There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness, as shown in the figure.


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ISUZU KB P190 2007

7B1-100 MANUAL TRANSMISSION

226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) W hite
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
• Use a pair of snap ring pliers to install the snap
ring to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
16. Install the top block ring.
Apply grease to the needle bearing inner and oute
r
circumferences and install the needle bearing in the
top gear shaft.
17. Use a bench press to install the top gear shaft ball bearing to the top gear shaft.


226RS059
The snap ring groove of the ball bearing must be
facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gea
r
shaft snap ring to the top gear shaft.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-101
Main Data and Specifications
General Specifications

MUA5G MUA5H MUA5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.008 4.357
2nd 2.301 2.301 2.502
3rd 1.427 1.427 1.501
4th 1.000 1.000 1.000
5th 0.828 0.744 0.809
Rev. 3.651 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"


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ISUZU KB P190 2007

7B1-102 MANUAL TRANSMISSION
Torque Specifications
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



RTW 77BLF003801
About arrow mark, refer to Transmission (MUA) Installation in this section.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-103
Torque Specifications (Cont'd)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)







RTW 77BLF003901


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ISUZU KB P190 2007

7B1-104 MANUAL TRANSMISSION
Torque Specifications (Cont'd)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



RTW 57BLF000301


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ISUZU KB P190 2007