ISUZU KB P190 2007 Workshop Repair Manual

MSG MODEL 7B-17
MAJOR COMPONENT

INTERNAL PARTS



Disassembly steps
1. Detent assembly
2. Shift arm assembly & interlock pin
3. Rev. and 5th gear assembly


4. Counter gear shaft assembly
5. Top & main gear shaft assembly



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ISUZU KB P190 2007

7B-18 MSG MODEL
MINOR COMPONENTS

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN


Disassembly Steps
1. Detent spring plate and gasket
2. Detent spring

3. Detent ball
4. Rev. - 5th shift rod
5. Rev. - 5th shift arm
6. 1st - 2nd shift rod



7. 3rd - 4th shift rod

8. 3rd - 4th shift arm

9. 1st - 2nd shift arm
10. Interlock pin
11. Intermediate plate and gear assembly



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ISUZU KB P190 2007

MSG MODEL 7B-19


Important Operations
3. Detent Ball



7. 3rd - 4th Shift Rod
8. 3rd - 4th Shift Arm
9. 1st - 2nd Shift Arm
1) Hold a round bar against the shift arm end.
This will prevent damage to other components.





2) Use a spring pin remover to remove the shift arm spring pin
from the shift arm and the shift rod.
Spring Pin Remover : 9-8529-2201-0
Discard the used spring pin.
3) Move the 3rd - 4th shift rod forward.
Take care not to lose the interlock pins.



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ISUZU KB P190 2007

7B-20 MSG MODEL
REVERSE GEAR AND 5TH GEAR


Disassembly Steps
1. Bearing snap ring
2. Speedometer drive gear and lock ball
3. Bearing spacer
4. Mainshaft end ball bearing
5. Thrust ring snap ring
6. Thrust washer thrust ring
7. Thrust washer and lock ball
8. Counter reverse gear nut and washer

9. Counter end ball bearing

10. Counter 5th gear
11. Counter reverse gear
12. 5th gear
13. 5th block ring
14. Needle bearing



15. Mainshaft lock nut and washer

16. Rev. - 5th synchronizer assembly
17. Reverse gear
18. Needle bearing
19. Needle bearing collar
20. Thrust washer
21. Counter reverse gear lock nut
22. Thrust washer
23. Reverse idler gear
24. Thrust washer
25. Reverse idler shaft

26. Bearing snap ring

27. Bearing snap ring

28. Intermediate plate



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ISUZU KB P190 2007

MSG MODEL 7B-21




Important Operations
9. Counter End Ball Bearing
10. Counter 5th Gear
Use a gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)




15. Mainshaft Lock Nut and Washer
1) Engage the 3rd - 4th synchronizer with the 3rd gear.
2) Engage the 1st - 2nd synchronizer with the 1st gear.
3) Attach a holding fixture to the mainshaft and the countergear.
Holding Fixture : 5-8840-2001-0 (J-29768)




4) Use a lock nut wrench to remove the lock nut.
Lock Nut W rench: 5-8840-0353-0 (J-36629)





16. Rev. - 5th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts






26. Bearing Snap Ring
1) Insert the snap ring pliers
1 into the counter gear bearing
snap ring hole
2.
The snap ring hole is in the intermediate plate
3.
2) Use the snap ring pliers to force open the counter gea
r
bearing snap ring.
Tap on the front of the intermediate plate.
The ball bearing snap ring will come free.


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ISUZU KB P190 2007

7B-22 MSG MODEL




27. Bearing Snap Ring
28. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap ring hole.
The snap ring hole is in the intermediate plate
2.
2) Use the snap ring pliers
1to force open the mainshaft
bearing snap ring
3.
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the transmission to remove it.
The ball bearing snap ring will come free.



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ISUZU KB P190 2007

MSG MODEL 7B-23
TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR



Disassembly Steps

1. Top gear shaft snap ring

2. Top gear shaft

3. Ball bearing
4. Needle bearing
5. 4th block ring
6. Mainshaft snap ring

7. 3rd - 4th synchronizer assembly
8. 3rd block ring
9. 3rd gear
10. Needle bearing

11. Mainshaft ball bearing
12. 1st gear thrust washer
13. 1st gear


14. Needle bearing collar
15. Needle bearing
16. 1st block ring

17. 1st - 2nd synchronizer assembly
18. 2nd block ring
19. 2nd gear
20. Needle bearing
21. Mainshaft

22. Rear ball bearing
23. Bearing snap ring

24. Front ball bearing
25. Counter gear



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ISUZU KB P190 2007

7B-24 MSG MODEL


Ball bearing J-22912-01


Important Operations
1. Top Gear Shaft Snap Ring
2. Top Gear Shaft
3. Ball Bearing
1) Use a pair of snap ring pliers to remove the snap ring.
2) Use a bench press and a bearing remover to remove the ball bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)



7. 3rd - 4th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts




11. Mainshaft Ball Bearing
Use a bench press and a bearing remover to remove the ball
bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)



17. 1st - 2nd Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts




22. Rear Ball Bearing
24. Front Ball Bearing
Use a bench press and a bearing remover to remove the ball
bearing.
Bearing Removar : 5-8840-0015-0 (J-22912-01)


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ISUZU KB P190 2007

MSG MODEL 7B-25
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.






SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness mm(in)
Standard Limit
1st-2nd 9.6-9.8 (0.378-0.386) 9.0 (0.354)
3rd-4th 6.95-7.2 (0.274-0.283) 6.5 (0.256)
Rev.-5th 6.8-6.9 (0.268-0.272) 6.3 (0.248)





DETENT SPRING FREE LENGTH
Use a venier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the detent
spring must be replaced.
Detent Spring Free Length mm(in)
Standard Limit
25.6 (1.01)23.6 (0.93)





DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension N(kg/lb)
Compressed
Height mm(in) Standard
Limit
22.1 (0.870)61.8-65.7
(6.3-6.7/13.9-14.8) 55.9
(5.7/12.6)



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.
Block Ring and Dog Teeth Clearance mm(in)
Standard Limit
1st,2nd 2.0 (0.079) 1.3 (0.051)
3rd, 4th, 5th 1.5 (0.059) 0.8 (0.031)


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ISUZU KB P190 2007

7B-26 MSG MODEL




BLOCK RING AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance mm(in)
StandardLimit
1st,2nd 3.46-3.74 (0.136-0.147)
3rd, 4th, 5th 3.51-3.79 (0.138-0.149)4.0 (0.157)





CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance mm(in)
Standard Limit
0.01 - 0.19 (0.0004 - 0.0075) 0.3 (0.012)



MAINSHAFT RUN - OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.
Mainshaft Run - Out mm(in)
Limit
Less than 0.03 (0.0012)





GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter mm(in)
Standard Limit
1st
Rev. 45.00-45.01
(1.7717-1.7720) 45.10 (1.7756)
2nd
3rd 41.00-41.01
(1.6142-1.6146) 41.10 (1.6181)
5th34.03-34.04
(1.3398-1.3402) 34.10 (1.3425)


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ISUZU KB P190 2007