ISUZU KB P190 2007 Workshop Repair Manual

MANUAL TRANSMISSION 7B1-75
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View








RTW 57BLF000201
Legend
(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly


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ISUZU KB P190 2007

7B1-76 MANUAL TRANSMISSION
Disassembly
1. Remove the detent spring plate and gasket, detent
spring and detent ball.
Use a magnetic hand to remove the detent balls
from the intermediate plate.


220RS011
2. Remove the spring.
3. Remove the rev-5th shift rod, and rev-5th shift arm and the reverse inhibitor.
Remove the 1st-2nd shift rod, 3rd-4th shift rod, 3rd-
4th shift arm, and 1st-2nd shift arm.
• Hold a round bar against the shift rod end.


230RS003
• Use a spring pin remover to remove the shift
arm spring pins from the shift arms and the shift
rods.



230RS0004
•
Be careful not to lose the interlock pins, when
pulling out the shift rod rearward.
The interlock pins are located between the
shifter rods in the intermediate plate.


230RS0005
• Remove the rev-5th, 1st-2nd and 3rd-4th shift
rods carefully.
4. Remove the interlock pin from intermediate plate and gear assembly.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-77
Inspection and Repair
Make the necessary adjustments 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
Standard Limit
1st-2nd 9.60 - 9.85 mm
(0.378 - 0.388 in)
3rd-4th
Rev.5th 9.60 - 9.80 mm
(0.378 - 0.386 in) 9.0 mm
(0.354 in)

230RS006
Detent Spring Free Length
• Use a vernier 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
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)

SOUTH AFRICA 5th-Rev Only
Detent Spring Free Length
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in)

220RS012
Detent Spring Tension

• Use a spring tester to measure the detent spring
tension.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent Spring Tension
Compressed height Standard
20 mm (0.787 in) 87.2 - 97.1 N
(19.6 - 21.8 lb)

220RS013

SOUTH AFRICA 5th-RV Only
Detent Spring Free Length
Compressed Standard
Outer 20 mm (0.787 in) 93.5 – 103.3 N
(21.0 – 23.3 lb)
Inner 20 mm (0.787 in) 26.4 – 36.3 N
(5.9 – 8.2 lb)

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ISUZU KB P190 2007

7B1-78 MANUAL TRANSMISSION
Reassembly
1. Install the rev-5th shift arm and reverse inhibitor and
rev-5th shift rod.
• Apply oil to the reverse inhibitor inner surface.
• Install the shift rod in the intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.
• Install the interlock pin in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
2. Install the 1st-2nd shift arm and 3rd-4th shift arm to the intermediate plate and gear assembly.
3. Install the 3rd-4th shift rod and the 1st-2nd shift rod. • Install the interlock pin in the intermediate plate
and gear assembly.
• Install the 3rd-4th shift rod in the intermediate
plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Install the interlock pin and then the 1st-2nd shift
rod in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.


230RS007
4. Install the spring.
5. Put the detent balls in the intermediate plate holes.• Apply oil to the detent balls.
6. Install the detent springs and detent spring plate and gasket.
NOTE: For South Africa model, it has double detent
spring for Rev-5th shift rod.
• Install a new gasket and the detent spring plate.
• Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)


220RS030
Legend
(1) W arped



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-79
Reverse Gear and 5th Gear
Disassembled View
226R300024

Legend
(1) Collar Snap Ring (15) Counter 5th Gear
(2) Oil Seal Collar (16) Counter Reverse Gear
(3) Ball Bearing (17) 5th Gear
(4) Retainer (18) 5th Block Ring
(5) Thrust Plate (19) Needle Bearing
(6) Thrust W asher and Lock Ball (20) Mainshaft Nut
(7) Reverse Idler Gear Snap Ring (21) Rev-5th Synchronizer Assembly
(8) Reverse Idler Gear Assembly (22) Reverse Block Ring
(9) Idle Shaft Pin (23) Reverse Gear
(10) Thrust W asher (24) Needle Baring
(11) Reverse Idler Gear (25) Bearing Plate and Screw
(12) Reverse Idler Shaft (26) Bearing Snap Ring
(13) Bearing Snap Ring (27) Intermediate Plate
(14) Ball Bearing


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ISUZU KB P190 2007

7B1-80 MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the collar
snap ring.
2. Set the mainshaft retainer remover 5-8840-2158-0 and puller 5-8840-2027-0 to the retainer and the
mainshaft end.
262RW 079
3. Remove the retainer together with the bearing and the oil seal collar.
The universal puller may be used in place of the
retaining ring remover.
4. Remove the thrust plate, thrust washer and lock ball.
5. Use a pair of snap ring pliers to remove reverse idle
r
gear snap ring.

226RS004

6. Remove the reverse idler gear assembly from the
intermediate plate.


226RS005
7. Remove the idle shaft pin, thrust washer, reverse idler gear, and reverse idler shaft.
8. Use a pair of snap ring pliers to remove the snap ring.
9. Attach a universal puller to the counter gear shaft. Use a universal puller to remove the ball bearing
and the counter 5th gear.


226RS006
10. Remove the counter reverse gear.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-81
11. Remove the 5th gear, 5th block ring, and needle
bearing (2 piece type).


226RS007
12. Remove the mainshaft nut according to following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counte
r
gear.
226RW 212
• Engage the 3rd-4th synchronizer with the 3rd
gear.
• Engage the 1st-2nd synchronizer with the 1st
gear.

226RW 210
•
Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut.
226RW 211





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ISUZU KB P190 2007

7B1-82 MANUAL TRANSMISSION
13. Use screw drivers between the reverse gear and the
bearing plate to remove the Rev-5th synchronize
r
assembly together with the reverse block ring and
reverse gear.


226RS010
14. Remove the needle bearing.
15. Use the torx bit wrench (T- 45) 5-8840-0047-0 to remove the bearing plate and screw from the
intermediate plate.

220RW 137
16. Use the snap ring pliers (1) to remove the mainshaft bearing snap ring (2).



226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate toward the rear of the
transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly. Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate on the gear assembly.
226RW 212



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-83
2. Install the bearing snap ring.
3.
Apply recommended thread locking agents
(LOCTITE 242) or equivalent to each of the bearing
plate screw threads.
Install the bearing plate and screw.
Tighten the screws to the specified torque by using
torx bit wrench (T- 45) 5-8840-0047-0.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)

220RW 137
4. Install the needle bearing, reverse gear and reverse block ring. 5. Assemble the rev-5th synchronizer assembly b
y
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the oute
r
circumference.
2. Check that the inserts (3) fit snugly into the clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.


226RS013

226RS049


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ISUZU KB P190 2007

7B1-84 MANUAL TRANSMISSION
6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).


226RS015
This will prevent the mainshaft from turning.
7. Install the new mainshaft hub nut. Use the mainshaft nut wrench 5-8840-2156-0 to
tighten the mainshaft nut to the specified torque.
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)
226RW 214


8. Use a punch to stake the mainshaft nut.


226RW 153
9. Install the needle bearing, 5th block ring, and 5th gear.
10.
Apply engine oil to the counter reverse gear and the
reverse gear.
Install the counter reverse gear to the counter shaft.
The reverse gear projection must be facing the
intermediate plate.


226RW 151




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ISUZU KB P190 2007