ISUZU KB P190 2007 Workshop Repair Manual

MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.


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ISUZU KB P190 2007

7B-8 MSG MODEL


Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.




Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation procedure.
2. Remove the 2nd propeller shaft flange yoke nuts at the drive pinion side
1.
3. Remove the center bearing retainer bolts
2 .
4. Remove the 1st propeller shaft with the center bearing and the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle until the spline yoke is free of the transmission main shaft.



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




Slave Cylinder
Remove the slave cylinder from the transmission case.


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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

7B-10 MSG MODEL



3) Manually move the transmission as far as possible toward
the rear of the vehicle (into the space between the No.3
crossmember
3 and the floor panel 4 .
4) Lower the clutch housing end of the transmission toward the transmission jack.
The rear of the transmission is supported by the No.3 crossmember at this time.
5) Firmly grasp the transmission rear cover (1st mechanic).
Raise the transmission jack toward the transmission (2nd mechanic).
Carefully lower the transmission onto the transmission jack.
The transmission must be centered on the transmission jack.


8. Carefully pull the transmission jack with the transmission
from beneath the vehicle.


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ISUZU KB P190 2007

MSG MODEL 7B-11
Important Operations - Installation
Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
installation procedure.



Transmission
1. Apply a thin coat of molybdenum disulfide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into position behind the engine.




4. Slowly operate the transmission jack to raise the
transmission until the rear of the transmission is at the
same level as the No.3 crossmember
1 .
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3 crossmember and the floor panel
2 .



6. Slowly raise 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.
7. Install the gear control box the transmission.
8. Align the top gear shaft spline with the clutch drive plate spline.
9. Install the transmission to the engine.
Tighten the transmission nuts and bolts as shown in the figure.




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ISUZU KB P190 2007

7B-12 MSG MODEL
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)

RTW 77BLF004201



10. Install the rear mounting rubber 3 to the transmission 2.
Install the rear mounting rubber
3 to the No.3
crossmember
4.
11. Tighten the rear mounting rubber nuts
1 to the specified
forque.
Rear Mounting Rubber Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
41 (4.2 / 30)
Mounting Bolt Torgue N⋅m (kgf ⋅m/lb ⋅ft)
41 (4.2 / 30)

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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

7B-14 MSG MODEL

Gear Shift Lever
1. Replenish the transmission case with the specified engineoil.
Transmission Case Oil lit(US gal.)
1.55 (0.41)


2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified torque.
Shift Lever Cover Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
20 (2.0 / 14)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.



Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.



Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.



Battery Cable
Connect the negative (-) cable to the battery terminal.



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ISUZU KB P190 2007

MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS





RTW 47BLF000301

Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly

6. Front cover with oil seal



7. Counter gear snap ring

8. Bearing snap ring
9. Rear cover with oil seal
10. Transmission case
11. Intermediate plate with gear assembly



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7B-16 MSG MODEL



Important Operations
6. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission
case.



7. Counter Gear Snap Ring
8. Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring.



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