ISUZU KB P190 2007 Workshop Repair Manual

7B1-2 Manual Transmission (MUX)
General Description
General Description
MUX5S Transmission(4x2 model)
RTW77BMF000701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-3
MUX5S Transmission(4x4 model)
The MUX5S is a constant mesh transmission,
synchronized in all speeds.
The transmission is designed for a reduction of the shift
effort and the quietest possible operation.
Principle parts of the transmission are the clutch
housing, the front case, the intermediate plate, the rear
case, the end cover, and the gears.
The transmission control box is built into the
transmission.
RTW77BMF000601

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7B1-4 Manual Transmission (MUX)
Troubleshooting
ConditionPossible Cause Correction
Abnormal Noise (Noisy in Neutral) Insufficient or improper lubricant Replenish or replace lubricant Flywheel pilot bearing worn or
broken Replace flywheel pilot bearing
Bearing(s) worn or broken (Input
shaft, counter shaft, and output
shaft) Replace bearing(s)
Gear tooth contact surfaces worn or
scuffed (Input shaft, counter shaft,
output shaft, and reverse idler gear) Replace gear(s)
Spline worn (Input shaft, output
shaft, counter shaft, and
synchronizer clutch hub) Replace worn parts
Transmission misalignment Realign transmission
Abnormal Noise (Noisy Operation) Insufficient or improper lubricant (Metallic rattling) Replenish or replace lubricant
Bearing(s) worn or broken (Hissing,
thumping, or bumping) Replace bearing(s)
Gear(s) worn, chipped, or cracked
(Growling, humming, or grinding) Replace gear(s)
Gears seizing on thrust face or
inner face free running (Squealing
at high speeds) Replace gear(s)
Gears lack of backlash between
meshing (Gear whining) Replace gear(s)
Hard Shifting Insufficient or improper lubricant Replenish or replace lubricant
Improper clutch pedal free play Readjust clutch pedal free play
Hard operating of change lever
caused insufficient grease Repair or regrease change lever
assembly
Change lever sliding portions worn Repair or replace applicable parts and regrease
Shift block sleeve movement failure Repair or replace sleeve
Shift rod and/or quadrant box
sliding face worn Replace worn parts
Shift arm and/or synchronizer
sleeve groove worn Replace worn parts
Collar, and/or gear thrust faces
worn (Input shaft and counter shaft
thrust play) Replace worn parts
Synchronizer parts worn Replace worn parts

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-5
Main Specifications
Walking or Jumping Out of Gear Change lever sliding portion wornand excessive playReplace worn parts
Shift rod and/or quadrant box
sliding faces worn Replace worn parts
Shift arm and synchronizer sleeve
groove worn Replace worn parts
Collar and/or gear thrust faces worn
(Input shaft and counter shaft thrust
play) Replace worn parts
Bearing worn or broken (Input shaft,
counter shaft, and individual gears) Replace bearing(s)
Input shaft spline, output shaft
spline, and synchronizer clutch hub
splines worn Replace input shaft, output shaft,
and synchronizer clutch hub
Synchronizer parts worn or broken Replace worn or broken parts
Taper bolt slack Replace taper bolt
Oil Leakage Oil level too high Drain oil to correct level Improper lubricant Replace lubricant
Drain plug and/or filler plug loose Tighten plug and replenish lubricant
Defective or improperly installed
gasket (s) Replace gasket(s)
Front oil seal worn or scratched Replace oil seal
Rear oil seal worn or scratched Replace oil seal
Model MUX5S
Transmission Type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor
Gear ratio 1st 4.326
2nd 2.557
3rd 1.490
4th 1.000
5th 0.790
Revese 3.942
Transmission oil capacity 3.0 lit. (3.17 US qt)
Type of lubricant BESCO TRANS AXLE OIL (5W-30 SF)
Condition
Possible Cause Correction

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7B1-6 Manual Transmission (MUX)
Fixing Torque
Legend

RTW77BLF001701
b
a
r
q
p
s
c
d
f
eg
h
i
j
l
k
mn
o
(a) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(b) 19 N ⋅m (1.9 kgf ⋅m/14 lb ⋅ft)
(c) 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(d) 83 N ⋅m (8.5 kgf ⋅m/61 lb ⋅ft)
(e) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(f) 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(g) 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
(h) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(i) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(j) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft) (k) 30 N
⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(l) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(m) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(n) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(o) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(p) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(q) 34 N ⋅m (3.5 kgf ⋅m/25 lb ⋅ft)
(r) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(s) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-7
Legend

RTW77BLF002901
t
u
v
w
y
x
(t) 9 N⋅m (0.9 kgf ⋅m/78 lb ⋅in)
(u) 47 N ⋅m (4.8 kgf ⋅m/35 lb ⋅ft)
(v) 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
(w) 36 N ⋅m (3.7 kgf ⋅m/27 lb ⋅ft) (x) 25 N
⋅m (2.5 kgf ⋅m/18 lb ⋅ft)
(y) 25 N ⋅m (2.5 kgf ⋅m/18 lb ⋅ft)

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7B1-8 Manual Transmission (MUX)
Transmission Assembly
Removal
1. Disconnect battery ground cable.
2. Remove the gear control knob.
3. Remove the rear floor console. (Bucket seat) Refer to the section "Floor Console".
4. Remove the front floor console. Refer to the section "Floor Console".
Legend 1. Gear control knob
2. Rear floor console
3. Front floor console

5. Remove the grommet assembly.
Legend 1. Grommet assembly
2. Floor panel
3. Front

6. Remove the gear control lever (1).
7. Raise and support vehicle with suitable stands.
8. Remove the rear propeller shaft.
RTW77BSH000101
1
32
RTW77BMH000101
1
2
3
RTW77BSH007101
1

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Manual Transmission (MUX) 7B1-9
• Apply alignment marks on the flange at thedifferential side.
9. Remove the front propeller shaft. (4x4 model) • Apply alignment marks on the flange at bothfront and rear side. 10. Disconnect the harness connectors and clips on
the transmission.
Legend 1. Neutral switch connector
2. Clutch damper valve connector

Legend 3. Clip
4. Reverse switch connector
5. 1st switch connector

RTW77BSH000201
RTW77BSH000201
RTW77BSH006601
1
2
RTW77BSH006701
3
3 54

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ISUZU KB P190 2007

7B1-10 Manual Transmission (MUX)
Legend6. Car speed sensor conector
7. Clip
8. 2-4 switch connector (4x4 model)
9. Neutral switch connector (4x4 model)
10. Transfer actuator connector (4x4 model)

11. Remove the harness bracket fixing bolt on the transmission left side.
12. Remove the slave cylinder fixing bolts.
13. Remove the fuel pipe bracket fixing bolt and disconnect fuel pipe clip.
14. Remove the clutch housing cover and clutch bearing dust cover.
15. Use the remover 5-8840-2291-0 to disconnect the clutch release bearing from the clutch pressure
plate.
a. Pull the shift fork toward the transmission to press the clutch release bearing against the
clutch. b. Insert the remover between the wedge collar
and the release bearing.
c. Turn the remover to separate the release bearing.
Notice:
Be sure not to insert the remover between the wedge
collar and the clutch.
Legend 1. Release bearing
2. Pressure plate assembly
3. Bearing remover : 5-8840-2291-0
4. Wedge collar

RTW77BSH006801
10 9
6
7 8
7
RTW77BSH000301
RTW77BSH000801
RTW77BSH000601
1
3
4
2

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-11
Legend1. Correct procedure
2. Wrong procedure
3. Front
4. Wedge collar
5. Clutch release bearing
6. Bearing remover : 5-8840-2291-0

• When clutch release bearing cannot be removed (For instance, transformation of
wedge collar, and other reasons), remove
the shift fork in order of the following with a
tool of L-type (2) as shown in figure.
1) Remove the snap pin (1).
2) Remove the shift fork pin (4).
3) Remove the shift fork (3). Notice:
Do not remove by this method usually.
The clutch release bearing or wedge collar might be
damaged with the input shaft of transmission at
removed the transmission because the clutch release
bearing is adhered to clutch.
16. Support transmission assembly (4x2 model) or transmission & transfer assembly (4x4 model) with
a transmission jack.
17. Remove the transmission rear mount nuts fixing on crossmember from the transmission crossmember.
18. Remove the transmission crossmember by removing four fixing bolts and nuts.
19. Remove the transmission rear mount.
20. Remove the starter assembly.
21. Disconnect harness clips on the transmission left side.
RTW77BLH000201
1
465
3
2
3
64
5
RTW77BSH006901
1
2
4 3
RTW77BSH000401

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ISUZU KB P190 2007