lock ISUZU KB P190 2007 Workshop Repair Manual

7B1-28 MANUAL TRANSMISSION
13. Use screw drivers between the reverse gear and the
bearing plate to remove the Rev-5th synchronize
r
assembly, together with the reverse block ring and
reverse gear.


226RS010
14. Remove the needle bearing.
15. Use the torx bit wrench (T- 45) 5-8840-0047-0 to remove the bearing plate and screw from the
intermediate plate.

220RW 137
16. Use the snap ring pliers (1) to remove the mainshaft bearing snap ring (2).



226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate toward the rear of the
transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly. Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear, and then install it on
the base 5-8840-0003-0.
Install the intermediate plate on the gear assembly.
226RW 212



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MANUAL TRANSMISSION 7B1-29
2. Install the bearing snap ring.
3.
Apply the recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install the bearing plate and screw.
Tighten the screws to the specified torque by using
torx bit wrench (T- 45) 5-8840-0047-0.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)

220RW 137
4. Install the needle bearing, reverse gear, and reverse block ring. 5. Assemble rev-5th synchronizer assembly b
y
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the oute
r
circumference.
2. Check that the inserts (3) fit snugly into the clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.


226RS013

226RS049


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7B1-30 MANUAL TRANSMISSION
6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).


226RS015
This will prevent the mainshaft from turning.
7. Install the new mainshaft hub nut. Use the mainshaft nut wrench 5-8840-2156-0 to
tighten the mainshaft nut to the specified torque.
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)
226RW 214


8. Use a punch to stake the mainshaft nut.


226RW 153
9. Install the needle bearing, 5th block ring, and 5th gear.
10.
Apply engine oil to the counter reverse gear and the
reverse gear.
Install the counter reverse gear to the counter shaft.
The reverse gear projection must be facing the
intermediate plate.


226RW 151




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ISUZU KB P190 2007

7B1-32 MANUAL TRANSMISSION
14. Select the reverse idler gear snap ring which will
provide the minimum clearance between the
intermediate plate and the snap ring.


226RS022
• There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
Snap Ring Availability
Thickness Color Coding
1.2 mm (0.047 in) W hite
1.3 mm (0.051 in) Yellow
1.4 mm (0.055 in) Blue

226RS021

• Use a pair of snap ring pliers to install the snap
ring to the reverse idler shaft.
The snap ring must be fully inserted into the
reverse idler shaft snap ring groove.
15. Install the thrust washer and lock ball by performing the following steps:
• Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in)
• Measure clearance "A" as shown in the figure.


226RS023
• Select an appropriate thrust washer from the
chart.
• There are four thrust washer sizes available.
Thrust Washer Availability
Thickness mm (in) Color
Coding A mm (in) Clearance
mm (in)
7.9 (0.311) W hite 8.05 - 8.1
(0.317-0.319) 0.15 - 0.25
(0.006-0.010)
8.0 (0.315) Yellow 8.1 - 8.2
(0.319-0.323) 0.1 - 0.25
(0.004-0.010)
8.1 (0.319) Green 8.2 - 8.3
(0.323-0.327) 0.1 - 0.25
(0.004-0.010)
8.2 (0.323) Blue 8.3 - 8.36
(0.327-0.329) 0.1 - 0.21
(0.004-0.008)
• The thrust washers are color-coded to indicate
their thickness, as shown in the figure.





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MANUAL TRANSMISSION 7B1-33

226RS024
• Apply grease to the thrust washer and the lock
ball.
• Install the thrust washer and the lock ball.
16. Install the thrust plate and retainer.
17. Install the retainer snap ring, clip, speedometer drive gear and bearing snap ring.
18.
Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
19. Install the bearing snap ring.




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MANUAL TRANSMISSION 7B1-35
Legend
(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring
(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft



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7B1-36 MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring.
2. Remove the top gear shaft with ball bearing.
3. Use a bench press and the bearing remover 5-8840- 0015-0 to remove the ball bearing.
226RW 216
4. Remove the needle bearing and top block ring,mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the mainshaft snap ring.


226RS008

6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronize
r
assembly as a set.
Disassemble the synchronizer assembly.
226RW 217
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove the 3rd block ring, 3rd gear, and needle bearing.
8. Use a bench press and the bearing remover 5-8840- 0015-0 to remove the 1st gear together with the
mainshaft ball bearing, 1st gear thrust bearing, and
needle bearing collar.
226RW 218




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MANUAL TRANSMISSION 7B1-37
9.Disassemble the 1st inside ring, 1st outside ring, and
1st block ring.
10.Remove the needle bearing.
11.Use a pair of snap ring pliers to remove the clutch hub snap ring.


226RS031
12.Use the bench press and the bearing remover 5-
8840-0015-0 to remove the 2nd gear together with
the 1st-2nd synchronizer assembly, 2nd block ring,
2nd outside ring, and the inside ring.
Disassemble the synchronizer assembly.
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Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
13. Remove the needle bearing from mainshaft.
14. Remove the bearing snap ring.
15. Remove the front roller bearing by performing the following steps.
• Remove the ring, outer race and bearing
assembly by using a bench press and remove
r
5-8840-0015-0.
• Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RW 219
16. Remove the center roller bearing from the counter
gear shaft.




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7B1-38 MANUAL TRANSMISSION
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Block Ring and Dog Teeth Clearance
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS035
If the measured value exceeds the specified limit,
the block ring must be replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)


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MANUAL TRANSMISSION 7B1-39
1st-2nd Synchronizer (3-CONE)
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)
Block Ring and Insert Clearance
• Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.


226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.157 in)
1st-2nd 3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th 3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)
Clutch Hub and Insert Clearance
• Use a thickness gauge to measure the clearance
between the clutch hub and the insert.


226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance
Standard Limit
1st-2nd3rd-4th 0.01 – 0.21 mm
(0.0004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th 0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)



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