ISUZU KB P190 2007 Workshop Repair Manual

7B1-32 Manual Transmission (MUX)
Snap Ring Availability51. Install the new snap ring to the output shaft. • Never reinstall the used snap ring.
52. Install the speedometer drive gear. (4x2 model)
53. Install the gear set clip. (4x2 model)
54. Install the end cover assembly.
• The gasket must be assembled. (4x2 model)
• Apply recommended liquid gasket (LOCTITE FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below. (4x4
model)
• Tighten the end cover bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
55. Install the speedometer driven gear and plate. (4x2 model)
56. Install the control rod detent assembly.
• Tighten the three detent assemblies to thespecified torque.
Torque: 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
57. Install the new 5th detent assembly and new reverse detent assembly.
• Never reinstall the used detent assembly.
• Tighten the three detent assemblies to the specified torque. Torque: 30 N
⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
58. Install the two harness brackets.
Torque: 8N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
59. Install the reverse switch (Connector color Brown), 1st switch (Connector color Gray) and neutral
switch (Connector color Brown) with gasket.
• Tighten the three switches to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
60. Install the control unit block by performing the following steps.
a. Push the control unit block ahead.
b. Install the control unit block.
c. Install the new taper bolt.
• Never reinstall the used taper bolt.
• Tighten the taper bolt to the specified torque.
Torque: 47 N ⋅m (4.8 kgf ⋅m/35 lb ⋅ft)
Important: • Must be checked no flaw to taper bolt.
• Must be checked no jam of foreign body before assembled.
• Must be checked same position upper surface of the taper bolt and the control unit block after
assembled.
61. Install the two dowels and quadrant box. • Apply recommended liquid gasket (LOCTITEFMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.
• Tighten the quadrant box bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
62. Remove the tape from the spline portion of the input shaft.
Thickness
Identification color
2.1 mm(0.083 in) White
2.2 mm(0.087 in) Blue
2.3 mm(0.091 in) Green
2.4 mm(0.094 in) Yellow
2.5 mm(0.098 in) Orange
2.6 mm(0.102 in) Black
RTW77BSH005601
RTW77BSH005701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-33
63. Install the front cover.• Tighten the front cover bolts to the specifiedtorque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
64. After reassembling the transmission, refill the case with the new specified transmission oil.
a. Install the drain plug with new gasket. • Never reinstall the used gasket.
• Apply engine oil to the new gasket surface.
• Tighten the drain plug to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
b. Remove the filler plug with gasket.
c. Refill the case with the new specified transmission oil (BESCO Trans Axle Oil 5W-30
SF) amount 3.0 liters.
d. Install the filler plug with new gasket. • Never reinstall the used gasket.
• Apply engine oil to the new gasket surface.
• Tighten the filler plug to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)

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ISUZU KB P190 2007

7B1-34 Manual Transmission (MUX)
Front Case Assembly
Component
Legend1. Front oil seal
2. Input shaft needle bearing
3. Front case with clutch housing
4. Reverse idler shaft 5. Reverse idler gear assembly
6. Reverse shaft bracket
7. Reverse idler bolt
8. Gasket

Removal
1. Remove the reverse idler bolt with gasket.
2. Remove the reverse shaft bracket and reverse idler gear assembly.
3. Remove the reverse idler shaft with straight pin.
RTW77BLF002301
1
2
34
5
6
8
7

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-35
4. Use the installer 5-8840-0125-0 (2) and grip 5-8840-0007-0 (1) to remove the front oil seal and
input shaft needle bearing from the front case, and
discard the used oil seal.
Installation
1. Use the installer 5-8840-2846-0 (2) and grip 5- 8840-0007-0 (1) to install the input shaft needle
bearing to the front case.
Notice:
Please install by making a stamp side into rear.
2. Install the front oil seal. a. Use the installer 5-8840-2846-0 (2) and grip 5- 8840-0007-0 (1) to install the new front oil seal
to the front case.
• Never reinstall the used oil seal.
• Apply engine oil to new front oil seal outer surfaces, and apply grease (BESCO L-2 or
equivalent) to the oil seal lip. • At press fitting the oil seal, to be careful not
to inflict lip of it.
b. The oil seal must be pressed fit as shown in the figure.
Legend 1. Front oil seal
2. 4 mm (0.157 in)
3. Front case

3. Install the reverse idler shaft with straight pin.
4. Install the reverse idler gear assembly and reverse shaft bracket.
• Apply engine oil to gear internal surface.
5. Install the reverse idler bolt with gasket.
• Tighten the reverse idler bolt to the specifiedtorque.
Torque: 83 N ⋅m (8.5 kgf ⋅m/61 lb ⋅ft)
RTW75CSH001201
1
2
RTW77BSH001901
1 2
RTW77BSH001901
12
RTW77BSH002001
2
1
3

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ISUZU KB P190 2007

7B1-36 Manual Transmission (MUX)
Rear Case Assembly
Component
Legend1. Linear ball bearing
2. Rear case
3. Output rear bearing outer race
4. Oil nozzle 5. Counter end roller bearing
6. Snap ring
7. Output front bearing outer race

Removal
1. Remove the linear ball bearing from the rear case.
2. Use a pair of snap ring pliers to remove the snap ring from the rear case.
3. Remove the counter end roller bearing from the rear case.
4. Remove the oil nozzle from the rear case.
RTW77BLF002401
1
7
2
3
5
6
4

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-37
5. Use the remover 5-8840-2757-0 (2) and slidinghammer 5-8840-0084-0 (1) to remove the output
front bearing outer race from the rear case.
6. Use the remover 5-8840-2757-0 (2) and sliding hammer 5-8840-0084-0 (1) to remove the output
rear bearing outer race from the rear case.Installation
1. Use the installer 5-8522-0053-0 (1) and grip 5- 8840-0007-0 (2) to install the output rear bearing
outer race to the rear case.
2. Use the installer 5-8840-2850-0 (1) and grip 5- 8840-0007-0 (2) to install the output front bearing
outer race to the rear case.
3. Install the oil nozzle to the rear case.
Important:
Convex of oil nozzle must be assembled in guide part
of rear case.
4. Install the counter shaft end roller bearing to the rear case.
5. Install the new snap ring to the rear case.
• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove of rear
case surely.
RTW77BSH002201
1
2
RTW77BSH002101
12
RTW75CSH001401
2 1
RTW75CSH001501
2
1

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ISUZU KB P190 2007

7B1-38 Manual Transmission (MUX)
6. Use the installer 5-8840-2848-0 (1) to install thelinear ball bearing to the rear case.
• The linear ball bearing to be pressed fit to front boss side.
• The linear ball bearing must be pressed at marked side.
RTW77BSH003101
1

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-39
End Cover Assembly
Component
Legend1. Rear oil seal (4x2 model)
2. End cover (4x2 model) 3. Rear oil seal (4x4 model)
4. End cover (4x4 modeel)

Removal
1. Remove the rear oil seal from the end cover, and discard the used oil seal.
Installation
1. Use the installer 5-8840-2786-0 to install the newrear oil seal to the end cover. (4x2 model)
Use the installer 5-8840-2282-0 (1) to install the
new rear oil seal to the end cover. (4x4 model)
• Never reinstall the used oil seal.
• Apply engine oil to new rear oil seal outer surfaces, and apply grease (BESCO L-2 or
equivalent) to the oil seal lip.
• At press fitting the oil seal, to be careful not to inflict lip of it.
RTW77BSF000501
1
2
3
4
RTW75CSH001301
1

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ISUZU KB P190 2007

7B1-40 Manual Transmission (MUX)
Input Shaft Assembly
Component
Legend1. 3rd input collar
2. 5th input collar
3. Input middle bearing 4. Oil catch impeller
5. Input shaft

Removal
1. Use a bench press to remove the 3rd input collar from the input shaft.
RTW77BMF001401
3
2
1
4
5
RTW75CSH000101

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-41
2. Use a bench press to remove the 5th input collarand input middle bearing from the input shaft.
3. Remove the oil catch impeller from the input shaft.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage or any other abnormal conditions are
found through inspection.
Input Shaft Run-out • Install the input shaft to V-blocks.
• Use a dial indicator to measure the input shaft central portion run-out.
If the measured input shaft run-out exceeds the
specified limit, the input shaft must be replaced. Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Installation
1. Install the oil catch impeller (1) to the input shaft.
Notice:
Direction of assembling exists. (Groove opening area
to be bearing side.)
Limit
0.05 mm
(0.002 in)
RTW75CSH000201
Standard Limit
0 - 0.066 mm
(0 - 0.0026 in) 0.1 mm
(0.004 in)
RTW77BSH002301
LNW25CSH029201

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