recommended oil ISUZU KB P190 2007 Workshop Manual PDF

7B1-18 MANUAL TRANSMISSION
4. Install a new gasket and gear control box assembly.
Install the harness clips and brackets and then
tighten four new gear control box bolts to the
specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
261R300004
5. Install the O-ring (3) to the speedometer driven gear
bushing (2).
Install the driven gear to the speedometer driven gear bushing (2).
6. Install the speedometer driven gear assembly to the transmission rear cover.
Install the plate (1) to the transmission rear cover.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
7. Install the speedometer sensor.
Torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kgf ⋅
⋅⋅
⋅
m/20 lb ⋅
⋅⋅
⋅
ft)



RTW 77BSH008501
8. Install top gear bearing snap ring and counter front
bearing snap ring.
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
9. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to a new oil seal, on the oute
r
circumference.
• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R3000020
10. Install a new gasket and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
Tighten the six front cover bolts to the specified
torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.6 kgf ⋅
⋅⋅
⋅
m/19 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

7B1-72 MANUAL TRANSMISSION
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case and drain the lubricant.
3. Remove the clutch release bearing with spring from the transmission case.
4. Remove the shift fork, and boot.
5. Remove the front cover and gasket from the transmission case.
6. Remove the snap ring fixing counter front bearing.
7. Use a pair of snap ring pliers to remove the snap ring fixing top gear bearing.


226RS001
8. Remove the gear control box assembly.
9. Remove the rear case assembly from the transmission case and intermediate plate.
10. Remove the intermediate plate with gear assembl
y
from the transmission case.

Rear Oil Seal Replacement
220R300025

Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard the used oil seal.
2. Apply engine oil to the new oil seal outer surfaces.
3.
Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 5- 8840-0007-0 to install the oil seal to the rear case.
Reassembly
1. Apply recommended liquid gasket (Three Bond TB1215) or its equivalent to the transmission case,
intermediate plate and rear case fitting surfaces.
2. Install the intermediate plate with gear assembly to the transmission case.
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal on the intermediate plate, with gear, by performing the following steps.
• Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
• Tighten the transmission rear case bolts and
nuts to the specified torque.
Torque: 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-73
mm (in)



RTW 77BSH008601

Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
4. Install a new gasket and gear control box assembly. Install the harness clips and brackets and then
tighten the four new gear control box bolts to the
specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
261R300004
5. Install the top gear bearing snap ring and counte
r
front bearing snap ring.
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to the outer circumference o
f
new oil seal.
• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R300002
7. Install a new gasket and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
Tighten the six front cover bolts to the specified
torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.6 kgf ⋅
⋅⋅
⋅
m/19 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-29
42. In order to protect the front oil seal lip, wrap a tapearound the spline portion of the input shaft.
43. Install the intermediate plate assembly with gear (1) to the front case.
• Apply recommended liquid gasket (LOCTITE FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below. 44. Install the magnet (1).
45. Remove the straight plug (1) from the rear case.
46. Install the rear case assembly.
RTW77BSH007601
1
4
3
2
RTW77BSH005801
RTW77BSH007501
1
RTW77BSH008201
1
RTW77BSH0063011

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ISUZU KB P190 2007

TRANSFER CASE 7D-7
Installation
1. Thoroughly clean around the oil seal bore in the case
and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.
3. Tap the oil seal in to place, use an oil seal installe
r
(5-8840-2785-0) and a soft hammer.



RTW 77DSH000301
4. Install the output flange to the front output shaft.
5. Apply the engine oil to the new O-ring and install it to the front output shaft.
6. Secure the output flange with a flange holde
r
(5-8840-0133-0).
7. Install the new end nut and tighten them to specified torque.
Front coupling driver fixing nut torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)

8. Use a punch (5-8840-2293-0) to caulk the end nut.




226R300012




RUW 34DSH000301
Legend
(1) MAX 26mm (1.02in)
(2) MIN 4mm (0.16in)


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ISUZU KB P190 2007

TRANSFER CASE 7D-9
Transfer Case Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts

220R300018
Legend

(1) Rear Propeller Shaft
(2) Rear Oil Seal

Removal

1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Remove the rear propeller shaft.
4. Remove the oil seal from the transfer case.

Installation
1. Thoroughly clean around the oil seal bore in the
transfer case and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.


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ISUZU KB P190 2007