ISUZU KB P190 2007 Workshop Repair Manual

MSG MODEL 7B-37



There are six thrust washer sizes available.

Thrust W asher Availability mm(in)
7.8 (0.307) 7.9 (0.311) 8.0 (0.315)
8.1 (0.319) 8.2 (0.323) 8.3 (0.327)
4) Position the thrust ring snap ring gap 1 and the thrust ring
gap
2 so that they are separated at a 90
° angle.



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ISUZU KB P190 2007

7B-38 MSG MODEL
DETENT AND SHIFT ARM ASSEMBLY



Reassembly Steps
1. Intermediate plate and gear assembly

2. 1st-2nd shift arm

3. 3rd-4th shift arm
4. Interlock pin
5. 3rd-4th shift rod
6. 1st-2nd shift rod



7. Rev.-5th shift arm
8. Rev.-5th shift rod
9. Detent ball
10. Detent spring

11. Detent spring plate and gasket




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MSG MODEL 7B-39



3rd & 4th
shift arm
1st & 2nd
shift arm Reverse & 5th shift arm
Important Operations
2. 1st-2nd Shift Arm
3. 3rd-4th Shift Arm
7. Rev.-5th Shift Arm
1) Hold a round bar against the shift rod end lower face to protect it against damage.
2) Use a spring pin installer to install the spring pin to the shift arm and the shift rod.
Never reinstall the used spring pins.



11. Detent spring Plate and Gasket.
1) Install the new detent plete and new gasket onto the transmission case into the correct direction.
2) Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
19 (1.9 / 14)



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7B-40 MSG MODEL
MAJOR COMPONENTS









RTW 47BLF000401

Reassembly steps
1. Intermediate plate with gear assembly

2. Rear cover with oil seal

3. Transmission case

4. Bearing snap ring
5. Counter gear snap ring



6. Front cover with oil seal
7. Speedometer driven gear
8. Gear control box assembly
9. Speedometer sensor
10. Clutch shift fork
11. Clutch shift block and release bearing



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ISUZU KB P190 2007

MSG MODEL 7B-41


RTW 47BSH000201
Important Operations
2. Rear Cover with Oil Seal
1)
Align the pins at the lower side of the rear cover with the
holes in the lower side of the intermediate plate.
2) Apply recommended liquid gasket (Three Bond TB1215) o
r
its equivalent to the rear cover fitting surfaces.
3) Install the rear cover to the intermediate plate.
4) Tighten the rear cover bolts to the specified torque.
Rear Cover Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
37 (3.8 / 27)
Note:
Take care not to twist or puncture the oil seal during the
installation procedure.




RTW 47BSH000301

3. Transmission Case
4. Bearing Snap Ring
1) Apply the engine oil to the transmission case top gear shaft ball bearing fitting faces.
2)
Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4) Pull the top gear shaft from the transmission case until the ball bearing snap ring grove protrudes from the
transmission case front cover fitting faces.
5) Use a pair of snap ring pliers to install the snap ring to the ball bearing.




6. Front Cover with Oil Seal
1) Clean and apply recommended liquid gasket or its equivalent to the through bolt threads.
2) Install the new gasket and tighten the new cover bolt to the specified torque.
Front Cover Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
25 (2.5 / 18)










RTW 47BSH000101
10. Shift Fork
Apply molybdenum disulfide type grease to the areas as shown in the figure and install shift fork (Diesel engine).



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7B-42 MSG MODEL
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

9-8529-2201-0
Spring pin remover
5-8840-0013-0
(J-22888) Gear remover
5-8840-2001-0
(J-29768) Holding fixture

5-8840-0353-0
(J-36629) Lock nut wrench
5-8840-0015-0
(J-22912-01) Bearing remover/installer
5-8840-0026-0
(J-26540) Oil seal installer

5-8522-0050-0
(J-29769) Oil seal installer

5-8840-0178-0
(J-33851) Collar installer


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-1
SECTION 7B1
MANUAL TRANSMISSION
(MUA)
TABLE OF CONTENTS
PAGE
MUA5G/5H/5S (4 ×
××
×
2)
Service Precaution ......................................................................................................... 7B 1 – 3
General Description ........................................................................................................ 7B 1 – 4
Rear Oil Seal ................................................................................................................. .. 7B1 – 5
Transmission (4 ×
××
×
2) ......................................................................................................... 7B1 – 7
Disassembled View..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –11
Transmission Case .......................................................................................................... 7B1 –16
Major Component........................................................................................................ 7B1 –16
Disassembly ................................................................................................................ 7B1 –17
Reassembly ................................................................................................................. 7B1 –17
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –20
Disassembled View..................................................................................................... 7B1 –20
Disassembly ................................................................................................................ 7B1 –21
Inspection and Repair................................................................................................. 7B1 –22
Reassembly ................................................................................................................. 7B1 –23
Reverse Gear and 5th Gear ............................................................................................ 7B1 –24 Disassembled View..................................................................................................... 7B1 –24
Disassembly ................................................................................................................ 7B1 –26
Inspection and Repair................................................................................................. 7B1 –28
Reassembly ................................................................................................................. 7B1 –28
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –34 Disassembled View..................................................................................................... 7B1 –34
Disassembly ................................................................................................................ 7B1 –36
Inspection and Repair................................................................................................. 7B1 –38
Reassembly ................................................................................................................. 7B1 –41
Main Data and Specifications ......................................................................................... 7B1 –47

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7B1-2 MANUAL TRANSMISSION
Troubleshooting .............................................................................................................. 7 B1 –51
Special Tools (4 ×
××
×
2) .......................................................................................................... 7B1 –58

MUA5G/5H/5S (4×
××
×
4)
Service Precaution ......................................................................................................... 7B 1 –59
General Description ........................................................................................................ 7B 1 –60
Transmission (4 ×
××
×
4) ......................................................................................................... 7B1 –61
Disassembled View..................................................................................................... 7B1 –61
Removal ....................................................................................................................... 7B1 –62
Installation ................................................................................................................... 7B1 –66
Transmission Case .......................................................................................................... 7B1 –71
Major Component........................................................................................................ 7B1 –71
Disassembly ................................................................................................................ 7B1 –72
Reassembly ................................................................................................................. 7B1 –72
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –75
Disassembled View..................................................................................................... 7B1 –75
Disassembly ................................................................................................................ 7B1 –76
Inspection and Repair................................................................................................. 7B1 –77
Reassembly ................................................................................................................. 7B1 –78
Reverse Gear and 5th Gear ............................................................................................ 7B1 –79 Disassembled View..................................................................................................... 7B1 –79
Disassembly ................................................................................................................ 7B1 –80
Inspection and Repair................................................................................................. 7B1 –82
Reassembly ................................................................................................................. 7B1 –82
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –88 Disassembled View..................................................................................................... 7B1 –88
Disassembly ................................................................................................................ 7B1 –90
Inspection and Repair................................................................................................. 7B1 –92
Reassembly ................................................................................................................. 7B1 –95
Main Data and Specifications ...................................................................................... 7B1 – 101
Troubleshooting ........................................................................................................... 7B1 – 105
Special Tools (4 ×
××
×
4) ....................................................................................................... 7B1 – 112


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MANUAL TRANSMISSION 7B1-3
Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNECESSARY SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require a
replacement after removal. ISUZU/GM will also call
out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

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7B1-4 MANUAL TRANSMISSION
General Description
MUA5G/5H/5S Transmission (4×
××
×
2)
A07R300006
The MUA5G/5H/5S is a constant mesh transmission,
synchronized in all speeds. The transmission has been
designed to provide low shift effort and low gear noise.
Principle parts of the transmission are the integral clutch
housing, the intermediate plate, the rear cover, and the
gears.
The transmission control box is built into the
transmission.



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