ISUZU KB P190 2007 Workshop Repair Manual

7B1-52 Manual Transmission (MUX)
Notice:
The snap ring must be assembled in groove of rod
surely.
6. Install the internal common upper lever.
7. Install the interlock middle block.
8. Install the internal common lower lever.
9. Install the interlock lower block.
10. Install the new snap ring to the interlock lower block lower side.
• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove of rod
surely.

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-53
Intermediate Plate Assembly
Component
Legend1. Intermediate plate
2. Reverse inhibitor bolt
3. Dowel
4. Input middle bearing snap ring
5. Straight pin 6. Reverse inhibitor spring
7. Reverse inhibitor
8. Reverse inhibitor snap ring
9. Linear ball bearing

Removal
1. Remove the reverse inhibitor snap ring.
2. Remove the reverse inhibitor and spring.
3. Remove the reverse inhibitor bolt.
4. Remove the straight pin.
5. Remove the linear ball bearing.
6. Remove the four dowels.
7. Use a pair of snap ring pliers to remove the input middle bearing snap ring.
Installation
1. Use a pair of snap ring pliers to install the newinput middle bearing snap ring.
• Never reinstall the used snap ring.
2. Install the four dowels. 3. Use the installer 5-8840-2848-0 (1) to install the
linear ball bearing.
Notice: • The bearing to be pressed fit to boss face.
• The bearing must be pressed at marked side.
RTW77BMF001001
9
3
1
2
3
3
3
4
5
6
7
8

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ISUZU KB P190 2007

7B1-54 Manual Transmission (MUX)
4. Install the straight pin.
5. Install the reverse inhibitor bolt.
• Tighten the reverse inhibitor bolt to thespecified torque.
Torque: 36 N ⋅m (3.7 kgf ⋅m/27 lb ⋅ft)
6. Install the reverse inhibitor and spring.
7. Install the new reverse inhibitor snap ring.
• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove of bolt
surely.
RTW77BSH002701
1

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-55
Control Rod Assembly
Component
Legend1. Control rod
2. Control unit lever
3. Control unit lever spring pin 4. Detent shift block
5. Detent shift block spring pin
6. Shift control seat

Removal
1. Remove the shift control seat.
2. Use a spring pin remover to remove the spring pin and the control unit lever.
3. Use a spring pin remover to remove the spring pin and the detent shift block.
Installation
1. Install the detent shift block and the new spring pin.
• Never reinstall the used spring pin.
Notice: • When assembled, vertical direction of block exists.
• The spring pin must be drive in to hole of end surface of block surely.
2. Install the control unit lever and the new spring pin. • Never reinstall the used spring pin. Notice:
The spring pin must be drive in to hole of end surface of
lever surely.
3. Install the shift control seat. • Apply grease to tip of sphere of lever and seat.
RTW77BMF001101
1
2
3
45
6

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ISUZU KB P190 2007

7B1-56 Manual Transmission (MUX)
5th-Reverse Shift Block Assembly
Component
Legend1. 5th-reverse shift lever
2. 5th-reverse shift block 3. Straight pin

Removal
1. Remove the straight pin and the 5th-reverse shift
lever.
Notice:
Make sure to remove the straight pin (2) in the direction
of 4.5 mm (0.177 in) diameter bore (1) side.
Installation
1. Install the 5th-reverse shift lever and the straight pin. Notice:
• Install the straight pin (2) from 4.5 mm (0.177 in) diameter bore (1) side, and adjust the setting
position to make the end of straight pin flush with
the end of the shift block.
• Installation direction of the lever to be not misassembled.
RTW77BSF000601
1
23
RTW77BSH007301
1
2
RTW77BSH007401
1
2

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-57
3rd-4th Shift Arm Assembly
Component
Legend1. Linear ball bearing 2. 3rd-4th shift arm

Removal
1. Remove the two linear ball bearings.
Installation
1. Use the installer 5-8840-2848-0 (1) to install the
two linear ball bearings.
Notice: • The bearing to be pressed fit to both boss faces.
• The bearing must be pressed at marked side.
RTW77BMF001201
1
2
1
RTW77BSH002801
1

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ISUZU KB P190 2007

7B1-58 Manual Transmission (MUX)
Special Tools
Special Tools
Illustration Tool Number/ Description5-8522-0053-0 (J-29016)Bearing Installer
5-8840-0007-0 (J-8092) Grip
5-8840-0084-0 (J-2619- 01)
Sliding Hammer
5-8840-0125-0 (J-26516) Pilot Bearing Installer
5-8840-2244-0 (J-5590) Bearing Installer
5-8840-2282-0 (J-36797) Oil Seal Installer
5852200530
5884022440
5-8840-2291-0 (J-39207)Bearing Remover
5-8840-2346-0 Installer
5-8840-2757-0 (J-45887) Bearing Remover
5-8840-2786-0 (J-46202) Oil Seal Installer
9-8522-1182-0 (J-35835) Bearing Installer
5-8840-2846-0
Oil Seal & Bearing Installer
Illustration Tool Number/ Description
5884022910
5884023460
5884027570
5884027860
9852211820
5884028460

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Manual Transmission (MUX) 7B1-59
5-8840-2847-0
Bearing Installer
5-8840-2848-0
Linear Ball Bearing Installer
5-8840-2849-0
Snap Ring Selector
5-8840-2850-0 (J-6197- A)
Bearing Installer
Illustration Tool Number/ Description
5884028470
5884028480
5884028490
5884028500

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ISUZU KB P190 2007

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description ........................................................................................................ 7C- 3
Torque Specification ....................................................................................................... 7C- 16
Servicing ...................................................................................................................... .... 7C-20
Clutch ......................................................................................................................... ...... 7C-22
Removal and Installation............................................................................................ 7C-22
Inspection and Repair ................................................................................................ 7C-26
Clutch Control................................................................................................................. . 7C-32
Removal and Installation............................................................................................ 7C-32
Master Cylinder................................................................................................................ 7C-33
Disassembly ................................................................................................................ 7C- 33
Reassembly ................................................................................................................. 7C- 34
Slave Cylinder (MSG, MUA) ............................................................................................ 7C-35 Disassembly ................................................................................................................ 7C- 35
Inspection and Repair ................................................................................................ 7C-36
Reassembly ................................................................................................................. 7C- 37
Slave Cylinder (MUX)....................................................................................................... 7C- 38
Disassembly ................................................................................................................ 7C- 38
Inspection and Repair ................................................................................................ 7C-39
Reassembly ................................................................................................................. 7C- 40
Hydraulic Damper Cylinder............................................................................................. 7C-41 Inspection and Repair ................................................................................................ 7C-41
Troubleshooting .............................................................................................................. 7 C-42
Special Service Tool........................................................................................................ 7C -51


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ISUZU KB P190 2007

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINE 4JJ1
(High Output) 4JA1-T 4JK1-TC 4JJ1 (Standard Output)
4JH1-TC C24SE
TRANSMISSION MUX MSG MUA MUA
Clutch type
Dry single plate with diaphragm
Size mm (in) 275 (10.83) 225 (8.86) 250 (9.84) 240 (9.45)
Clamping force kg(lb) 700 (1544) 517 (1140) 640 (1411) 560 (1235)
(N) (6860) (5070) (6300) (5500)
Pressure plate
Outside diameter mm(in) 275 (10.83) 225 (8.86) 250 (9.84) 240 (9.45)
Inside diameter mm(in) 180 (7.087) 150 (5.906) 160 (6.299) 160 (6.299)
Driven plate
Thickness mm(in)
at free 8.8 (0.346) 8.4 (0.331) 8.3 (0.327) 8.7 (0.342)
at compressed 8.3 (0.327) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)
Clutch Cont. type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Master cylinder
Bore×Stroke mm(in) 15.87 × 35 (0.625 × 1.38)
Slave cylinder
Bore × Stroke mm(in) 22.22 × 18.9
(0.875 × 0.744) 19.05
× 23
(0.749 × 0.906) 20.64
× 23
(0.813 × 0.906) 19.05
× 23
(0.749 × 0.906)


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ISUZU KB P190 2007