start ISUZU KB P190 2007 Workshop Repair Manual

7A3-20 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION ASSEMBLY

RUW 57ALF000201
Legend
1. Shift Cable
2. Propeller Shaft
3. Engine Harness
4. ATF Level Dipstick & Filler Tube
5. Under Cover
6. Bolt

7. ATF Pipe
8. Crossmember
9. Transmission Mount
10. Starter Motor
11. Bolt
12. Automatic Transmission

Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with the suitable safety stands.




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ISUZU KB P190 2007

MSG MODEL 7B-9
Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.




Starter Motor
Remove the starter motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the No.3
crossmember
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.


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ISUZU KB P190 2007

MSG MODEL 7B-13




Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Torque N⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0 / 58)




Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque N ⋅m (kgf ⋅m/lb ⋅ft
)
78 (8.0 / 58)

Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.




Rear Propeller Shaft (Dual Shaft Type)
1. Place the center bearing and retainer 1 together with the
1st propeller shaft
2 and 2nd propeller shaft 7on the No.4
crossmember
3.
2. Insert the splined yoke
4 into the transmission main shaft
spline
5.
3. Tighten the center bearing retainer bolts
6 to the specified
torque.
Center Bearing Retainer Bolt Torque N ⋅m (kgf ⋅m/lb ⋅ft)
61 (6.2 / 45)



4. Connect the 2nd propeller shaft
7 and drive pinion side 8.
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
M8 : 35 (3.6 / 26)
M10 : 63 (6.4 / 46)




Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the 2nd
exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-7
Transmission (4×
××
×
2)
Disassembled View



RTW 77BLF003201
Legend
(1) Gear Control Lever Knob (9) Slave Cylinder
(2) Rear Floor Console (bucket seat) (10) Nut: rear mount to Crossmember
(3) Front Floor Console (11) Transmission Crossmember
(4) Grommet Assembly (12) Nut: rear mount to transmission
(5) Gear Control Lever (13) Rear Mount Rubber
(6) Rear Propeller Shaft (14) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (15) Transmission Retaining Nut and Bolt
(8) Fuel Pipe Bracket (16) Transmission Assembly




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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-11
17. Take out the rear mount rubber.
18. Remove the starter (Diesel engine only).
060L100070
19. Remove transmission retaining nuts and bolts. Remove the transmission assembly from the
vehicle.

Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of the transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must be the same.
3.
Align the top gear shaft spline with the clutch driven
plate spline.
4. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts as shown in
the figure.



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ISUZU KB P190 2007

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 7B1-61
Transmission (4×
××
×
4)
Disassembled View



RTW 77BLF003601
Legend
(1) Gear Control Lever Knob (10) Transfer Assembly
(2) Rear Floor Console (bucket) (11) Fuel Pipe Bracket
(3) Front Floor Console (12) Slave Cylinder
(4) Grommet Assembly (13) Rear Mount Nut
(5) Gear Control Lever (14) Transmission Crossmember
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Front Propeller Shaft (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe Nut (Diesel engine) (17) Transmission Assembly
(9) Transmission-Transfer Fixing Bolt



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-65
16. Remove the engine rear mount bolts fixing
transmission.
220R300009
17. Remove the middle part of the transmissioncrossmember by removing the four fixing bolts and
nuts.
501R30007
18. Take out the rear support rubber. 19. Remove the starter. (Diesel engine only)
060L100070
20. Remove the transmission retaining nuts and bolts.
Remove the transmission assembly from the
vehicle.
21. Remove the transmission–transfer fixing bolts and nut, and disassemble the transfer from the
transmission.



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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) 7B1-11
Legend1. Correct procedure
2. Wrong procedure
3. Front
4. Wedge collar
5. Clutch release bearing
6. Bearing remover : 5-8840-2291-0

• When clutch release bearing cannot be removed (For instance, transformation of
wedge collar, and other reasons), remove
the shift fork in order of the following with a
tool of L-type (2) as shown in figure.
1) Remove the snap pin (1).
2) Remove the shift fork pin (4).
3) Remove the shift fork (3). Notice:
Do not remove by this method usually.
The clutch release bearing or wedge collar might be
damaged with the input shaft of transmission at
removed the transmission because the clutch release
bearing is adhered to clutch.
16. Support transmission assembly (4x2 model) or transmission & transfer assembly (4x4 model) with
a transmission jack.
17. Remove the transmission rear mount nuts fixing on crossmember from the transmission crossmember.
18. Remove the transmission crossmember by removing four fixing bolts and nuts.
19. Remove the transmission rear mount.
20. Remove the starter assembly.
21. Disconnect harness clips on the transmission left side.
RTW77BLH000201
1
465
3
2
3
64
5
RTW77BSH006901
1
2
4 3
RTW77BSH000401

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ISUZU KB P190 2007