lock ISUZU KB P190 2007 Workshop Repair Manual

UNIT REPAIR (JR405E) 7A4-35
Return springs • Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2
• Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter – 8.0 mm (0.315 in)
Free length – 27.1 mm (1.067 in)
Linear diameter – 1.1 mm (0.043 in)


10R&H40

Reverse clutch piston
• Apply compressed air (390 kPa/4.0 kgf/cm
2/57 psi) to
the reverse clutch piston from the outside to the inside.
The flow of air should be blocked.


11R&H44

•
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to
the reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.


12R&H39

Reassembly steps
Coat the parts with ATF before installing them.
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.


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ISUZU KB P190 2007

7A4-48 UNIT REPAIR (JR405E)

25C&L-SUB27

4. Side plate
Install the side plate.


26C&L-SUB26

5. Snap ring
Install the snap ring to the low clutch drum.


27C&L-SUB58

•
Attach the low one-way clutch inner race to the low
clutch drum in the opposite direction of the normal
position.
• Rotate the one-way clutch inner race clockwise. It
should turn smoothly with little resistance.
• Rotate the low one-way clutch inner race
counterclockwise.
It should immediately lock (rotation is impossible).
If it does not, check the low one-way clutch installation
direction.
Inspect and replace the low one-way clutch if required.
• Remove the low one-way clutch inner race.
• Reverse the low clutch drum.


28C&L-SUB32

6. Low clutch piston
• Install new seal rings to the low clutch piston.


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ISUZU KB P190 2007

MSG MODEL 7B-3
GENERAL DESCRIPTION


The MSG type transmission is fully synchronized 5-speed unit with blocking ring type synchronizers and a constant
mesh type reverse gear.
The unit consists principally of a case with an integral clutch housing, intermediate plate, rear cover and gears.
The top of the rear cover is a quadrant box containing the transmission control mechanism.
The case and rear cover are cast aluminum alloy to reduce weight.


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ISUZU KB P190 2007

MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS





RTW 47BLF000301

Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly

6. Front cover with oil seal



7. Counter gear snap ring

8. Bearing snap ring
9. Rear cover with oil seal
10. Transmission case
11. Intermediate plate with gear assembly



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ISUZU KB P190 2007

MSG MODEL 7B-17
MAJOR COMPONENT

INTERNAL PARTS



Disassembly steps
1. Detent assembly
2. Shift arm assembly & interlock pin
3. Rev. and 5th gear assembly


4. Counter gear shaft assembly
5. Top & main gear shaft assembly



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ISUZU KB P190 2007

7B-18 MSG MODEL
MINOR COMPONENTS

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN


Disassembly Steps
1. Detent spring plate and gasket
2. Detent spring

3. Detent ball
4. Rev. - 5th shift rod
5. Rev. - 5th shift arm
6. 1st - 2nd shift rod



7. 3rd - 4th shift rod

8. 3rd - 4th shift arm

9. 1st - 2nd shift arm
10. Interlock pin
11. Intermediate plate and gear assembly



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ISUZU KB P190 2007

MSG MODEL 7B-19


Important Operations
3. Detent Ball



7. 3rd - 4th Shift Rod
8. 3rd - 4th Shift Arm
9. 1st - 2nd Shift Arm
1) Hold a round bar against the shift arm end.
This will prevent damage to other components.





2) Use a spring pin remover to remove the shift arm spring pin
from the shift arm and the shift rod.
Spring Pin Remover : 9-8529-2201-0
Discard the used spring pin.
3) Move the 3rd - 4th shift rod forward.
Take care not to lose the interlock pins.



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ISUZU KB P190 2007

7B-20 MSG MODEL
REVERSE GEAR AND 5TH GEAR


Disassembly Steps
1. Bearing snap ring
2. Speedometer drive gear and lock ball
3. Bearing spacer
4. Mainshaft end ball bearing
5. Thrust ring snap ring
6. Thrust washer thrust ring
7. Thrust washer and lock ball
8. Counter reverse gear nut and washer

9. Counter end ball bearing

10. Counter 5th gear
11. Counter reverse gear
12. 5th gear
13. 5th block ring
14. Needle bearing



15. Mainshaft lock nut and washer

16. Rev. - 5th synchronizer assembly
17. Reverse gear
18. Needle bearing
19. Needle bearing collar
20. Thrust washer
21. Counter reverse gear lock nut
22. Thrust washer
23. Reverse idler gear
24. Thrust washer
25. Reverse idler shaft

26. Bearing snap ring

27. Bearing snap ring

28. Intermediate plate



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ISUZU KB P190 2007

MSG MODEL 7B-21




Important Operations
9. Counter End Ball Bearing
10. Counter 5th Gear
Use a gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)




15. Mainshaft Lock Nut and Washer
1) Engage the 3rd - 4th synchronizer with the 3rd gear.
2) Engage the 1st - 2nd synchronizer with the 1st gear.
3) Attach a holding fixture to the mainshaft and the countergear.
Holding Fixture : 5-8840-2001-0 (J-29768)




4) Use a lock nut wrench to remove the lock nut.
Lock Nut W rench: 5-8840-0353-0 (J-36629)





16. Rev. - 5th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts






26. Bearing Snap Ring
1) Insert the snap ring pliers
1 into the counter gear bearing
snap ring hole
2.
The snap ring hole is in the intermediate plate
3.
2) Use the snap ring pliers to force open the counter gea
r
bearing snap ring.
Tap on the front of the intermediate plate.
The ball bearing snap ring will come free.


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ISUZU KB P190 2007

MSG MODEL 7B-23
TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR



Disassembly Steps

1. Top gear shaft snap ring

2. Top gear shaft

3. Ball bearing
4. Needle bearing
5. 4th block ring
6. Mainshaft snap ring

7. 3rd - 4th synchronizer assembly
8. 3rd block ring
9. 3rd gear
10. Needle bearing

11. Mainshaft ball bearing
12. 1st gear thrust washer
13. 1st gear


14. Needle bearing collar
15. Needle bearing
16. 1st block ring

17. 1st - 2nd synchronizer assembly
18. 2nd block ring
19. 2nd gear
20. Needle bearing
21. Mainshaft

22. Rear ball bearing
23. Bearing snap ring

24. Front ball bearing
25. Counter gear



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ISUZU KB P190 2007