engine ISUZU KB P190 2007 Workshop Repair Manual

7B1-44 MANUAL TRANSMISSION

226RS031
9. Install the needle bearing, 1st block ring, 1st outside
ring , 1st inside ring, and 1st gear.
•
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
• The 1st gear dog teeth must be facing the
transmission front side.


226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
10. Install the 1st gear thrust bearing and the race to the
main shaft.
The thrust bearing side must be facing the
transmission front side.


226RS054
11. Apply engine oil to the mainshaft ball bearing and the mainshaft.
Install the ball bearing and needle bearing collar to
the mainshaft.
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.


226RS055



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MANUAL TRANSMISSION 7B1-45
12. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing and the 3rd gear to the
mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.


226RS056
13. Install the 3rd block ring.
14. Check and install the 3rd-4th synchronizer assembl
y
using the following steps:
1. Check that the inserts (3) fit snugly into the clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the inserts, as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be facing the 3rd gear side.


226RS049

226RW 221
15. Select and install mainshaft snap ring using the
following instructions:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.


226RS058
There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness as shown in the figure.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-47
Main Data and Specifications
General Specifications
MUA 5G MUA 5H MUA 5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.008 4.357
2nd 2.301 2.301 2.502
3rd 1.427 1.427 1.501
4th 1.000 1.000 1.000
5th 0.828 0.744 0.809
Rev. 3.651 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"


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7B1-52 MANUAL TRANSMISSION
2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil
NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)W orn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)W orn, chipped, or cracked
gear(s)
NG
NG
NG
NG
OK
OK
OK
OK
Gear oil (Metallic rattling)



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MANUAL TRANSMISSION 7B1-53
2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
W orn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OK NG
NG
NG
NG
OK
OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxW orn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG
NG
OKShift block sleeve movement


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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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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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7B1-64 MANUAL TRANSMISSION
12. Remove the fuel pipe brackets with pipes from the
transmission.
Diesel engine
220R300012
Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly





C24SE
Scan-2
13. Remove the slave cylinder and put it aside.
220LV019
14. Support the transmission with a transmission jack.
220RS0001
15. Remove the engine rear mount nuts from the
transmission crossmember.




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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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7B1-66 MANUAL TRANSMISSION
Installation
1. Apply grease (BESCO L2 or equivalent) on the
splined portion of the output shaft.
2. Connect the transfer to the transmission.
3. Install the transmission-transfer bolts and nut and tighten them to the specified torque.
Torque: 41 N ⋅
⋅⋅
⋅
m (4.2 kgf ⋅
⋅⋅
⋅
m/30 lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BMF001501

4. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
5. 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.
6.
Align the top gear shaft with the clutch driven plate
spline.
7. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts, as shown in
the figure.


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