Neutral switch ISUZU KB P190 2007 Workshop Owners Manual

7B1-14 MANUAL TRANSMISSION
5. Install the starter. (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
6. Install the rear support rubber on the transmission and tighten the nuts to the specified torque.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
7. Install the middle part of the transmission crossmember and the bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
8. Install the engine rear mount nuts fixing on the transmission crossmember.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from transmission
side.
9. Apply grease to the top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
10. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
Nut 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly






C24SE
Scan-1
11. Connect the transmission harness connectors and
clip. Connector: neutral switch, car speed sensor,
and backup switch.
12. Tighten the exhaust pipe fixing nuts to the specified torque. (Diesel engine only)
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)





RTW 67BSH000101



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-63
6. Remove the gear control lever.
7. Raise and support the vehicle with suitable stands.
8. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.
9. Remove the front propeller shaft.
NOTE:
Apply alignment marks on the flange at both
front and rear sides.
401RS023
10. Loosen the front exhaust pipe fixing nuts at the engine side but do not remove them. (Diesel engine
only)





RTW 67BSH000101
11. Disconnect the harness connectors and clips on the
transmission and transfer.
• Neutral Switch: Transmission
• Back up Switch
• Actuator
• 2W D-4W D Switch
• Neutral Switch: Transfer
• Car Speed Sensor

810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Back up Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W D - 4W D Switch Connector
(6) Neutral Switch Connector: Transfer


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-69
8. Install the starter. (Diesel engine)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
9. Install the rear support rubber on the transmission and tighten the bolts to the specified torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
10. Install the middle part of transmission crossmember and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
11. Install the engine rear mount nuts.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from the
transmission side.
12. Apply grease to top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
13. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe brackets
Torque: Bolt & Nut 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
Nut 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly





C24SE
Scan-2
14. Connect the transmission harness connectors and
clips. Connector: transfer neutral switch, 2W D -
4W D switch, actuator, car speed sensor, backup
switch, transmission neutral switch.
810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Backup Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W D - 4W D Switch connector
(6) Neutral Switch Connector: Transfer


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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-9
• Apply alignment marks on the flange at thedifferential side.
9. Remove the front propeller shaft. (4x4 model) • Apply alignment marks on the flange at bothfront and rear side. 10. Disconnect 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

RTW77BSH000201
RTW77BSH000201
RTW77BSH006601
1
2
RTW77BSH006701
3
3 54

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ISUZU KB P190 2007

7B1-10 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)

11. Remove the harness bracket fixing bolt on the transmission left side.
12. Remove the slave cylinder fixing bolts.
13. Remove the fuel pipe bracket fixing bolt and disconnect fuel pipe clip.
14. Remove the clutch housing cover and clutch bearing dust cover.
15. Use the remover 5-8840-2291-0 to disconnect the clutch release bearing from the clutch pressure
plate.
a. Pull the shift fork toward the transmission to press the clutch release bearing against the
clutch. b. Insert the remover between the wedge collar
and the release bearing.
c. Turn the remover to separate the release bearing.
Notice:
Be sure not to insert the remover between the wedge
collar and the clutch.
Legend 1. Release bearing
2. Pressure plate assembly
3. Bearing remover : 5-8840-2291-0
4. Wedge collar

RTW77BSH006801
10 9
6
7 8
7
RTW77BSH000301
RTW77BSH000801
RTW77BSH000601
1
3
4
2

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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

RTW77BSH000301
RTW77BSH006601
1
2
RTW77BSH006701
3
3 54

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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".
RTW77BSH006801
10 9
6
7 8
7
RTW77BSH007101
1
RTW77BMH000101
1
2
3

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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

RTW77BLF001901
16
1718191314
1
23
22
20
12
13
14
2
3
4
5
6
21
21
11
10
9
8
7
15

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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.
RTW77BSH006001
RTW77BSH003901
2
1
RTW77BSH008101
1
2
RTW77BSH007501
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