lock ISUZU KB P190 2007 Workshop Repair Manual

MSG MODEL 7B-25
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, 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 mm(in)
Standard Limit
1st-2nd 9.6-9.8 (0.378-0.386) 9.0 (0.354)
3rd-4th 6.95-7.2 (0.274-0.283) 6.5 (0.256)
Rev.-5th 6.8-6.9 (0.268-0.272) 6.3 (0.248)





DETENT SPRING FREE LENGTH
Use a venier 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 mm(in)
Standard Limit
25.6 (1.01)23.6 (0.93)





DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension N(kg/lb)
Compressed
Height mm(in) Standard
Limit
22.1 (0.870)61.8-65.7
(6.3-6.7/13.9-14.8) 55.9
(5.7/12.6)



BLOCK RING AND DOG TEETH
CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance mm(in)
Standard Limit
1st,2nd 2.0 (0.079) 1.3 (0.051)
3rd, 4th, 5th 1.5 (0.059) 0.8 (0.031)


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ISUZU KB P190 2007

7B-26 MSG MODEL




BLOCK RING AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance mm(in)
StandardLimit
1st,2nd 3.46-3.74 (0.136-0.147)
3rd, 4th, 5th 3.51-3.79 (0.138-0.149)4.0 (0.157)





CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance mm(in)
Standard Limit
0.01 - 0.19 (0.0004 - 0.0075) 0.3 (0.012)



MAINSHAFT RUN - OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.
Mainshaft Run - Out mm(in)
Limit
Less than 0.03 (0.0012)





GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter mm(in)
Standard Limit
1st
Rev. 45.00-45.01
(1.7717-1.7720) 45.10 (1.7756)
2nd
3rd 41.00-41.01
(1.6142-1.6146) 41.10 (1.6181)
5th34.03-34.04
(1.3398-1.3402) 34.10 (1.3425)


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ISUZU KB P190 2007

MSG MODEL 7B-29
REASSEMBLY

MAJOR COMPONENT
INTERNAL PARTS


Reassembly steps
1. Top & main gear shaft assembly
2. Counter gear shaft assembly
3. Rev. and 5th gear assembly


4. Shift arm assembly & interlock pin
5. Detent assembly



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ISUZU KB P190 2007

7B-30 MSG MODEL
MINOR COMPONENTS

TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR


Reassembly Steps
1. Mainshaft

2. Needle bearing

3. 2nd gear
4. 2nd block ring

5. 1st-2nd synchronizer assembly
6. 1st block ring

7. Needle bearing collar

8. Needle bearing

9. 1st gear

10. 1st gear thrust washer

11. Mainshaft ball bearing

12. Needle bearing

13. 3rd gear


14. 3rd block ring

15. 3rd-4th synchronizer assembly

16. Mainshaft snap ring
17. Needle bearing
18. 4th block ring

19. Top gear shaft

20. Ball bearing
21. Top gear shaft snap ring
22. Counter gear
23. Front ball bearing
24. Bearing snap ring

25. Rear ball bearing



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ISUZU KB P190 2007

7B-34 MSG MODEL
REVERSE GEAR AND 5TH GEAR



Reassembly Steps

1. Intermediate plate

2. Reverse idler shaft
3. Bearing snap ring
4. Bearing snap ring
5. Thrust washer

6. Reverse idler gear
7. Thrust washer

8. Counter reverse gear lock nut

9. Thrust washer
10. Needle bearing collar
11. Needle bearing
12. Reverse gear

13. Rev.-5th synchronizer assembly

14. Mainshaft lock nut and washer


15. Needle bearing
16. 5th block ring
17. 5th gear

18. Thrust washer and lock ball
19. Counter reverse gear
20. Counter 5th gear
21. Counter end ball bearing

22. Counter reverse gear nut and washer

23. Thrust washer thrust ring

24. Thrust ring snap ring
25. Mainshaft end ball bearing
26. Bearing spacer
27. Speedometer drive gear and lock ball
28. Bearing snap ring




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ISUZU KB P190 2007

MSG MODEL 7B-35


Important Operations
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque N⋅m(kgf ⋅m/lb ⋅ft)
19 (1.9 / 14)




3) Set the mainshaft with gear assembly

1 and the counter
gear assembly
2 to a holding fixture
3.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the counte
r
shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the counter gear ball bearings.




6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
108 (11 / 80)



9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse gear side.


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ISUZU KB P190 2007

7B-36 MSG MODEL


13. Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer
1 and the insert short side 2
must be facing to the rear side of the transmission.



14. Mainshaft Lock Nut and Washer
1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use a lock nut wrench to tighten the lock nut to the specified torque.
Lock Nut W rench : 5-8840-0353-0 (J-36629)
Lock Nut Torque N⋅m(kgf ⋅m/lb ⋅ft)
127 (11 / 94)



22. Counter Reverse Gear Nut and Washer
Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque N⋅m(kgf ⋅m/lb ⋅ft)
108 (11 / 80)



18. Thrust Washer and Lock Ball
23. Thrust Washer Thrust Ring
24. Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.


3) Use a thickness gauge to measure the clearance between
the 5th gear and the thrust washer.
5th Gear and Thrust W asher Clearance mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.


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ISUZU KB P190 2007

7B-38 MSG MODEL
DETENT AND SHIFT ARM ASSEMBLY



Reassembly Steps
1. Intermediate plate and gear assembly

2. 1st-2nd shift arm

3. 3rd-4th shift arm
4. Interlock pin
5. 3rd-4th shift rod
6. 1st-2nd shift rod



7. Rev.-5th shift arm
8. Rev.-5th shift rod
9. Detent ball
10. Detent spring

11. Detent spring plate and gasket




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ISUZU KB P190 2007

7B-40 MSG MODEL
MAJOR COMPONENTS









RTW 47BLF000401

Reassembly steps
1. Intermediate plate with gear assembly

2. Rear cover with oil seal

3. Transmission case

4. Bearing snap ring
5. Counter gear snap ring



6. Front cover with oil seal
7. Speedometer driven gear
8. Gear control box assembly
9. Speedometer sensor
10. Clutch shift fork
11. Clutch shift block and release bearing



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ISUZU KB P190 2007

7B-42 MSG MODEL
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

9-8529-2201-0
Spring pin remover
5-8840-0013-0
(J-22888) Gear remover
5-8840-2001-0
(J-29768) Holding fixture

5-8840-0353-0
(J-36629) Lock nut wrench
5-8840-0015-0
(J-22912-01) Bearing remover/installer
5-8840-0026-0
(J-26540) Oil seal installer

5-8522-0050-0
(J-29769) Oil seal installer

5-8840-0178-0
(J-33851) Collar installer


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ISUZU KB P190 2007