ISUZU KB P190 2007 Workshop Repair Manual

7B1-12 Manual Transmission (MUX)
22. Remove the transmission retaining nuts and bolts.Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.
23. Remove the transmission-transfer fixing bolts and nut, and disassemble the transfer from the
transmission. (4x4 model)
Installation
1. Apply grease (BESCO L-2 or equivalent) on the splined portion of the output shaft.
2. Connect the transfer to the transmission. (4x4 model)
3. Install the transmission-transfer fixing bolts and nut, and tighten them to the specified torque. (4x4
model)
Torque: 41 N ⋅m (4.2 kgf ⋅m/30 lb ⋅ft)
4. Apply a thin coat of molybdenum disulfide grease on the splined portion of the input shaft spline.
5. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the
engine.
6. Align the input shaft spline with the clutch driven plate spline.
7. Install the transmission assembly (4x2 model) or the transmission & transfer assembly (4x4 model)
to the engine.
• Tighten the transmission bolts to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
8. Apply a force 69 N ⋅m (7 kgf ⋅m/51 lb ⋅ft) to the tip of
the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.
Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N ⋅m (2.6 kgf ⋅m/19 lb ⋅ft). If
the shift fork will not move, then they are securely
engaged. 9. Connect harness clips on the transmission left
side.
10. Install the starter assembly.
• Tighten the starter bolts to the specified torque.
Torque: 94 N ⋅m (9.6 kgf ⋅m/69 lb ⋅ft)
11. Install the transmission rear mount to the transmission.
• Tighten the transmission rear mount bolts to the specified torque.
Torque: 50 N ⋅m (5.1 kgf ⋅m/37 lb ⋅ft)
12. Install the transmission crossmember by removing four bolts and nuts.
• Tighten the transmission crossmember bolts to the specified torque.
Torque: 67 N ⋅m (6.8 kgf ⋅m/49 lb ⋅ft)
13. Install the transmission rear mount nuts fixing on crossmember from transmission crossmember.
• Tighten the transmission rear mount nuts to the specified torque.
Torque: 52 N ⋅m (5.3 kgf ⋅m/38 lb ⋅ft)
Remove the transmission jack from transmission
side.
14. Install the fuel pipe bracket bolt and connect fuel pipe clip.
• Tighten the fuel pipe bracket bolt to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
15. Install the slave cylinder fixing bolts. • Tighten the slave cylinder bolts to the specifiedtorque.
Torque: 43 N ⋅m (4.4 kgf ⋅m/32 lb ⋅ft)
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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-13
16. Install the front propeller shaft. (4x4 model)• Tighten the front propeller shaft bolts to thespecified torque.
Torque: 59 N ⋅m (6.0 kgf ⋅m/43 lb ⋅ft)
17. Install the rear propeller shaft.
• Tighten the rear propeller shaft bolts to thespecified torque.
Torque
Rear flange: 59 N ⋅m (6.0 kgf ⋅m/43 lb ⋅ft)
Center bearing: 69 N ⋅m (7.0 kgf ⋅m/51 lb ⋅ft)
18. Connect harness clip on the transmission left side bracket.
Install the harness bracket bolt.
• Tighten the harness bracket bolt to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft) 19. Connect the harness connectors and clips on the
transmission.
Legend 1. Neutral switch connector
2. Clutch damper valve connector

Legend 3. Clip
4. Reverse switch connector
5. 1st switch connector

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ISUZU KB P190 2007

7B1-14 Manual Transmission (MUX)
Legend6. Car speed sensor conector
7. Clip
8. 2-4 switch connector (4x4 model)
9. Neutral switch connector (4x4 model)
10. Transfer actuator connector (4x4 model)

20. Install the clutch housing cover and clutch bearing dust cover.
• Tighten the clutch housing cover bolts and clutch bearing dust cover bolts to the specified
torque.
Torque: 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
21. Install the gear control lever (1). • Tighten the gear control lever bolts to thespecified torque.
Torque: 19 N ⋅m (1.9 kgf ⋅m/14 lb ⋅ft)
22. Install the grommet assembly. • Tighten the grommet bolts to the specifiedtorque. Torque
Screw: 1.4 N ⋅m (0.14 kgf ⋅m/12 lb ⋅in)
Nut: 7 N ⋅m (0.7 kgf ⋅m/61 lb ⋅in)
Legend 1. Grommet Assembly
2. Floor Panel
3. Front

23. Install the front floor console. Refer to the section "Floor Console".
24. Install the rear floor console. (Bucket seat) Refer to the section "Floor Console".
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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-15
25. Install the gear control knob.
Legend 1. Knob
2. Rear Floor Console
3. Front Floor Console

26. Connect battery ground cable.
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ISUZU KB P190 2007

7B1-16 Manual Transmission (MUX)
Transmission
Component
Legend1. Front case assembly with clutch housing
2. Front cover
3. Reverse switch
4. 1st switch
5. Reverse detent assembly
6. Neutral switch
7. Intermediate plate assembly
8. 5th detent assembly
9. Filler plug
10. Drain plug 11. Rear case assembly
12. End cover assembly (4x4 model) 13. Output shaft snap ring
14. Output rear bearing inner race
15. Speedometer driven gear
16. End cover assembly (4x2 model)
17. End cover gasket
18. Gear set clip
19. Speedometer drive gear
20. Straight plug
21. Dowel
22. Control rod detent assembly
23. Quadrant box

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-17
Legend24. Control unit block
25. Taper bolt
26. Control rod assembly
27. Rear gutter
28. Counter 5th gutter
29. Front gutter
30. Counter 2nd gutter
31. Reverse shift arm apring pin
32. Reverse shift arm
33. 1st-2nd shift arm spring pin
34. 1st-2nd shift arm
35. Intermediate plate assembly
36. Magnet 37. 1st-2nd shift block spring pin
38. 1st-2nd shift block
39. 1st-2nd shift rod
40. Reverse shift rod
41. Reverse shift rod snap ring
42. 3rd-4th-5th shift rod
43. 3rd-4th-5th shift rod snap ring
44. 3rd-4th shift arm assembly
45. 5th-Reverse shift block assembly
46. 5th shift arm
47. 5th shift arm spring pin
48. Shift rod bracket
49. Shift & select rod assembly

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ISUZU KB P190 2007

7B1-18 Manual Transmission (MUX)
Legend50. Output shaft assembly
51. Pilot bearing
52. Pilot bearing spacer
53. 3rd-4th hub snap ring
54. 3rd-4th block ring
55. Plate spring
56. 3rd-4th synchronizer assembly
57. 3rd input gear needle bearing
58. 3rd input gear assembly
59. 5th hub snap ring
60. 5th synchronizer assembly 61. 5th block ring
62. 5th input gear needle bearing (2 piece type)
63. 5th input gear assembly
64. Input shaft assembly
65. Rubber seal
66. Counter end snap ring
67. Output counter gear
68. 3rd counter gear
69. 5th counter gear
70. Counter middle roller bearing outer race
71. Counter shaft assembly

Removal
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug with gasket and drain the lubricant.
3. Remove the front cover. 4. In order to protect the front oil seal lip, wrap a tape
around the spline portion of the input shaft.
5. Remove the quadrant box and two dowels.
6. Remove the control unit block by performing the following steps.
a. Push the control unit block ahead.
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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-19
b. Remove the taper bolt, and discard the usedtaper bolt.
c. Remove the control unit block.
7. Remove the reverse switch (Connector color Brown), 1st switch (Connector color Gray) and
neutral switch (Connector color Brown) with
gasket.
Remove the three detent assemblies, and discard
the used 5th & reverse detent assemblies.
8. Remove the two harness brackets.
9. Remove the speedometer driven gear and plate. (4x2 model)
10. Remove the end cover assembly. 11. Remove the gear set clip. (4x2 model)
12. Remove the speedometer drive gear. (4x2 model)
13. Stand the transmission assembly.
14. Remove the output shaft snap ring (1).
15. Remove the output rear bearing inner race (2).
16. Remove the rear case assembly (1). 17. Remove the magnet (2).
18. Remove the intermediate plate assembly with gear (1) from the front case.
19. Remove the tape from the spline portion of the input shaft.
20. Remove the front gutter (1) and rear gutter (3), and discard the used gutters.
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ISUZU KB P190 2007

7B1-20 Manual Transmission (MUX)
21. Remove the counter 2nd gutter (4) and counter 5thgutter (2).
22. Remove the shift rod bracket (1).
23. Remove the shift & select rod assembly (1). 24. Remove the control rod assembly (1).
25. Use a spring pin remover to remove the 1st-2nd shift arm spring pin.
26. Remove the shift rod (2) with the 1st-2nd shft block (3).
27. Remove the 1st-2nd shift arm (1).
28. Use a spring pin remover to remove the reverse shift arm spring pin.
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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-21
29. Remove the reverse shift rod snap ring (1).
30. The shift block lever is put into the dent of the 3rd-4th-5th shift rod.
Legend 1. 3rd-4th-5th shift rod
2. Dent of 3rd-4th-5th shift rod
3. 5th-reverse shift block
4. Reverse shift rod
5. Shift block lever
6. 123.5 mm (4.86 in)

31. Remove the reverse shift rod.
32. Remove the reverse shift arm.
33. Use a spring pin remover to remove the 5th shift arm spring pin. 34. Remove the 3rd-4th-5th shift rod snap ring (1).
35. Remove the 3rd-4th-5th shift rod.
36. Remove the 5th shift arm.
37. Remove the 5th-reverse shift block assembly.
38. Remove the 3rd-4th shift arm assembly.
39. Remove the output shaft assembly.
40. Remove the rubber seal, and discard the used rubber seal.
41. Remove the counter end snap ring (1).
42. Remove the output counter gear.
43. Remove the pilot bearing.
44. Remove the pilot bearing spacer.
45. Remove the 3rd-4th block ring of the output shaft side.
46. Remove the plate spring.
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ISUZU KB P190 2007