lock ISUZU KB P190 2007 Workshop Repair Manual

7B1-26 Manual Transmission (MUX)
14. Install the plate spring.
Notice:
Painted identification color (Blue) side to be
Transmission rear side.
Legend 1. Transmission rear side
2. Painted area of identification color (Blue)

15. Install the 3rd-4th block ring of output shaft side.
16. Install the output counter gear.
• Apply engine oil to the gear internal surface.
17. Install the new counter end snap ring (1). • Never reinstall the used snap ring.
• Choose the thickest snap ring among ones whitch can be assembled.
Snap Ring Availability 18. Use the installer 5-8840-2346-0 (1) to install the
new rubber seal.
• Never reinstall the used rubber seal.
• When seal press fitted, clearance not exists between lip and end surface of gear.
19. Install the pilot bearing spacer.
20. Install the pilot bearing. • Apply grease (BESCO L-2 or equivalent) to thebearing roller.
21. Install the output shaft assembly.
22. Install the 3rd-4th shift arm assembly.
23. Install the 5th-reverse shift block assembly.
24. Install the 5th shift arm.
25. Install the 3rd-4th-5th shift rod.
26. Install the new 3rd-4th-5th shift rod snap ring (1).
• Never reinstall the used snap ring.
Thickness
Identification color
2.3 mm(0.091 in) Pink
2.5 mm(0.098 in) White
RTW77BSH005001
1
RTW77BSH008801
1
2
2.7 mm(0.106 in) Green
Thickness
Identification color
RTW77BSH005201
1
RTW77BSH003601
1

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-27
27. Install the 5th shift arm new spring pin.• Never reinstall the used spring pin.
Notice:
The spring pin must be drive in to this hole end surface
surfly.
28. Install the reverse shift arm.
29. 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)

30. Install the reverse shift rod. Notice:
The dents (1) of the shift rod should face outside of the
transmission so that the detent of the front case fits
them when reassembled.
31. Install the new reverse shift rod snap ring (1). • Never reinstall the used snap ring.
32. Install the reverse shift arm new spring pin. • Never reinstall the used spring pin.
Notice:
The spring pin must be drive in to this hole end surface
surfly.
33. Install the 1st-2nd shift arm (1).
RTW77BSH004901
1
RTW77BSH004801
1
6
2
5
4
3
RTW77BSH005301
1
RTW77BSH004701
1

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ISUZU KB P190 2007

7B1-28 Manual Transmission (MUX)
34. Install the shift rod (2) with the 1st-2nd shft block(3).
35. Install the 1st-2nd shift arm new spring pin. • Never reinstall the used spring pin.
Notice:
The spring pin must be drive in to this hole end surface
surfly.
36. Install the control rod assembly (1). 37. Install the shift & select rod assembly (1) and bolts
temporarily.
38. Install the shift rod bracket (1) and bolts temporarily.
39. Install the bolts to the shift & select rod assembly and shift rod bracket.
• Tighten the shift & select rod bolts and the shift rod bracket bolts to the specified torque.
Torque: 25 N ⋅m (2.5 kgf ⋅m/18 lb ⋅ft)
40. Install the counter 2nd gutter (4) and counter 5th gutter (2).
• Tighten the gutter bolts to the specified torque.
Torque: 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
41. Install the new front gutter (1) and new rear gutter (3).
• Never reinstall the used gutters.
RTW77BSH008001
3
2
1
RTW77BSH007901
1
RTW77BSH007801
1
RTW77BSH007701
1

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ISUZU KB P190 2007

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) 7B1-41
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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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-43
Counter Shaft Assembly
Component
Legend1. Reverse counter snap ring
2. Counter front roller bearing outer race
3. Counter front roller bearing inner race
4. Reverse synchronizer assembly
5. Reverse block ring
6. Reverse counter gear assembly
7. Reverse counter gear needle bearing
8. 1st counter snap ring
9. 1st counter collar
10. 1st counter gear assembly 11. 1st counter gear needle bearing
12. 1st-2nd inside ring
13. 1st-2nd outside ring
14. 1st-2nd block ring
15. 1st-2nd synchronizer assembly
16. 2nd counter gear assembly
17. 2nd counter gear needle bearing
18. Counter shaft
19. Counter middle roller bearing inner race

Removal
1. Use a pair of snap ring pliers to remove the reverse counter snap ring.
2. Remove the counter front roller bearing outer race.
RTW77BLF001601
1 2 3 4 5 6 7
8 9 10 11
12
13
19
18
17
16
12
13
14
15
14

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ISUZU KB P190 2007

7B1-44 Manual Transmission (MUX)
3. Use a bench press to remove the reverse countergear assembly together with reverse block ring,
reverse synchronizer assembly, and counter front
roller bearing inner race.
4. Remove the reverse counter gear needle bearing.
5. Remove the 1st counter snap ring.
6. Use a bench press to remove the 2nd counter gear assembly together with 1st-2nd synchronizer
assembly, inside ring, outside ring, block ring, 1st
counter gear assembly, and 1st counter collar. 7. Use a bench press to remove the counter middle
roller bearing inner race.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage or any other abnormal conditions are
found through inspection.
Block Ring and Dog Teeth Clearance
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the
block ring must be replaced.
RTW75CSH000601
RTW75CSH000701
Standard Limit
Reverse 1.5 mm
(0.059 in) 0.8 mm
(0.031 in)
RTW75CSH000501
LNW25CSH028401

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-45
1st-2nd Synchronizer (3-CONE)
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the
1st-2nd synchronizer assembly must be replaced.
Block Ring and Insert Clearance
Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and insert.
If the measured value exceeds the specified limit, the
block ring and insert must be replaced. Clutch Hub and Insert Clearance
Use a thickness gauge to measure the clearance
between the clutch hub and insert.
If the measured value exceeds the specified limit, the
clutch hub and insert must be replaced.
Counter Shaft Run-out • Install the counter shaft to V-blocks.
• Use a dial indicator to measure the counter shaft central portion run-out.
If the measured counter shaft run-out exceeds the
specified limit, the counter shaft must be replaced.
Standard Limit
1.5 mm
(0.059 in) 0.8 mm
(0.031 in)
Standard Limit
1st - 2nd 3.86 - 4.16 mm
(0.152 - 0.164 in) 4.4 mm
(0.173 in)
Reverse 2.16 - 2.46 mm
(0.085 - 0.097 in) 2.7 mm
(0.106 in)
LNW25CSH028501
Standard Limit
1st - 2nd Reverse 0.01 - 0.21 mm
(0.0004 - 0.0083 in) 0.3 mm
(0.0118 in)
RTW77BSH006501
LNW25CSH028701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-47
Installation
1. Install the needle bearing, 2nd counter gearassembly, 2nd inside ring, 2nd outside ring, and
2nd block ring.
• Apply engine oil to the needle bearing and gear internal surface.
2. Assemble the 1st-2nd synchronizer assembly by performing the following steps.
• Check that the inserts (1) fit snugly into the clutch hub (4) insert grooves.
• Check that the inserts springs (2) are fitted to the inserts as shown in the figure.
• Check that the clutch hub (4) and sleeve (3) slide smoothly.
• The insert springs (2) must be set in such a way that the opening of each spring faces different
direction. 3. Use a bench press and installer 9-8522-1182-0 (1)
to install the 1st-2nd synchronizer assembly, 1st
block ring, 1st outside ring and 1st inside ring.
• Apply engine oil to the block ring internal surface.
4. Install the needle bearing and 1st counter gear assembly.
• Apply engine oil to the needle bearing and gear internal surface.
5. Use a bench press and installer 9-8522-1182-0 (1) to install the 1st counter collar.
Notice:
The collar must be press fitted with end surface of
sleeve & hub.
Standard
Limit
Front 0 - 0.098 mm
(0 - 0.0039 in) 0.15 mm
(0.0059 in)
LNW25CSH029201
LNW45CSH002301
1
23
4
RTW75CSH000901
1

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7B1-48 Manual Transmission (MUX)
6. Install the new 1st counter snap ring.• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove surely.
7. Install the needle bearing, reverse block ring, and reverse counter gear assembly.
• Apply engine oil to the needle bearing and gear internal surface.
8. Use a bench press and installer 5-8840-2244-0 (1) to install the reverse synchronizer assembly.
• Apply engine oil to the block ring internal surface. 9. Use a bench press and installer 5-8840-2346-0 (1)
to install the counter front roller bearing inner race.
10. Install the counter front roller bearing outer race. 11. Use a pair of snap ring pliers to install the new reverse counter snap ring.
• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove surely.
12. Install the counter middle roller bearing by performing the following steps.
a. Use a bench press and installer 5-8840-2847-0 (1) to install the counter middle roller bearing
inner race.
b. Install the counter middle roller bearing outer race.
Notice: • Direction of assembling exists. (Flange of inner race to be shaft side.)
RTW75CSH001001
1
RTW75CSH001101
1
RTW75CSH000801
1
RTW77BSH002501
1

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