torque ISUZU KB P190 2007 Workshop Repair Manual

7B-14 MSG MODEL

Gear Shift Lever
1. Replenish the transmission case with the specified engineoil.
Transmission Case Oil lit(US gal.)
1.55 (0.41)


2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified torque.
Shift Lever Cover Bolt Torque Nâ‹…m(kgf â‹…m/lb â‹…ft)
20 (2.0 / 14)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.



Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.



Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.



Battery Cable
Connect the negative (-) cable to the battery terminal.



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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 Nâ‹…m(kgf â‹…m/lb â‹…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 Nâ‹…m (kgf â‹…m/lb â‹…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 Nâ‹…m(kgf â‹…m/lb â‹…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 Nâ‹…m(kgf â‹…m/lb â‹…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

MSG MODEL 7B-39



3rd & 4th
shift arm
1st & 2nd
shift arm Reverse & 5th shift arm
Important Operations
2. 1st-2nd Shift Arm
3. 3rd-4th Shift Arm
7. Rev.-5th Shift Arm
1) Hold a round bar against the shift rod end lower face to protect it against damage.
2) Use a spring pin installer to install the spring pin to the shift arm and the shift rod.
Never reinstall the used spring pins.



11. Detent spring Plate and Gasket.
1) Install the new detent plete and new gasket onto the transmission case into the correct direction.
2) Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque Nâ‹…m(kgf â‹…m/lb â‹…ft)
19 (1.9 / 14)



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MSG MODEL 7B-41


RTW 47BSH000201
Important Operations
2. Rear Cover with Oil Seal
1)
Align the pins at the lower side of the rear cover with the
holes in the lower side of the intermediate plate.
2) Apply recommended liquid gasket (Three Bond TB1215) o
r
its equivalent to the rear cover fitting surfaces.
3) Install the rear cover to the intermediate plate.
4) Tighten the rear cover bolts to the specified torque.
Rear Cover Bolt Torque Nâ‹…m(kgf â‹…m/lb â‹…ft)
37 (3.8 / 27)
Note:
Take care not to twist or puncture the oil seal during the
installation procedure.




RTW 47BSH000301

3. Transmission Case
4. Bearing Snap Ring
1) Apply the engine oil to the transmission case top gear shaft ball bearing fitting faces.
2)
Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4) Pull the top gear shaft from the transmission case until the ball bearing snap ring grove protrudes from the
transmission case front cover fitting faces.
5) Use a pair of snap ring pliers to install the snap ring to the ball bearing.




6. Front Cover with Oil Seal
1) Clean and apply recommended liquid gasket or its equivalent to the through bolt threads.
2) Install the new gasket and tighten the new cover bolt to the specified torque.
Front Cover Bolt Torque Nâ‹…m(kgf â‹…m/lb â‹…ft)
25 (2.5 / 18)










RTW 47BSH000101
10. Shift Fork
Apply molybdenum disulfide type grease to the areas as shown in the figure and install shift fork (Diesel engine).



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-3
Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNECESSARY SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require a
replacement after removal. ISUZU/GM will also call
out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

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7B1-6 MANUAL TRANSMISSION
Torque : 63 Nâ‹…
â‹…â‹…
â‹…
m (6.4 kgf â‹…
â‹…â‹…
â‹…
m/46 lb â‹…
â‹…â‹…
â‹…
ft)
4. Install center bearing on crossmember.
Torque : 69 N â‹…
â‹…â‹…
â‹…
m (7.0 kgf â‹…
â‹…â‹…
â‹…
m/51 lb â‹…
â‹…â‹…
â‹…
ft)
5. Check transmission fluid level.
6. Lower the vehicle.




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7B1-14 MANUAL TRANSMISSION
5. Install the starter. (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N â‹…
â‹…â‹…
â‹…
m (7.7 kgf â‹…
â‹…â‹…
â‹…
m/56 lb â‹…
â‹…â‹…
â‹…
ft)
6. Install the rear support rubber on the transmission and tighten the nuts to the specified torque.
Torque: 52 N â‹…
â‹…â‹…
â‹…
m (5.3 kgf â‹…
â‹…â‹…
â‹…
m/38 lb â‹…
â‹…â‹…
â‹…
ft)
7. Install the middle part of the transmission crossmember and the bolts.
Tighten the nuts to the specified torque.
Torque: 67 N â‹…
â‹…â‹…
â‹…
m (6.8 kgf â‹…
â‹…â‹…
â‹…
m/49 lb â‹…
â‹…â‹…
â‹…
ft)
8. Install the engine rear mount nuts fixing on the transmission crossmember.
Torque: 52 N â‹…
â‹…â‹…
â‹…
m (5.3 kgf â‹…
â‹…â‹…
â‹…
m/38 lb â‹…
â‹…â‹…
â‹…
ft)
Remove the transmission jack from transmission
side.
9. Apply grease to the top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N â‹…
â‹…â‹…
â‹…
m (7.7 kgf â‹…
â‹…â‹…
â‹…
m/56 lb â‹…
â‹…â‹…
â‹…
ft)
10. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N â‹…
â‹…â‹…
â‹…
m (7.7 kgf â‹…
â‹…â‹…
â‹…
m/56 lb â‹…
â‹…â‹…
â‹…
ft)
Nut 37 N â‹…
â‹…â‹…
â‹…
m (3.8 kgf â‹…
â‹…â‹…
â‹…
m/27 lb â‹…
â‹…â‹…
â‹…
ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly






C24SE
Scan-1
11. Connect the transmission harness connectors and
clip. Connector: neutral switch, car speed sensor,
and backup switch.
12. Tighten the exhaust pipe fixing nuts to the specified torque. (Diesel engine only)
Torque: 67 N â‹…
â‹…â‹…
â‹…
m (6.8 kgf â‹…
â‹…â‹…
â‹…
m/49 lb â‹…
â‹…â‹…
â‹…
ft)





RTW 67BSH000101



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MANUAL TRANSMISSION 7B1-15
13. Install the rear propeller shaft.
Torque: 59 N â‹…
â‹…â‹…
â‹…
m (6.0 kgf â‹…
â‹…â‹…
â‹…
m/43 lb â‹…
â‹…â‹…
â‹…
ft)
14. Install the center bearing on crossemember.
Torque: 69 N â‹…
â‹…â‹…
â‹…
m (7.0 kgf â‹…
â‹…â‹…
â‹…
m/51 lb â‹…
â‹…â‹…
â‹…
ft)
15. Install the gear control lever.
Torque: 19 N â‹…
â‹…â‹…
â‹…
m (1.9 kgf â‹…
â‹…â‹…
â‹…
m/14 lb â‹…
â‹…â‹…
â‹…
ft)
16. Install the grommet assembly.
Torque: Screw 1.4 N â‹…
â‹…â‹…
â‹…
m (0.14 kgf â‹…
â‹…â‹…
â‹…
m/12 lb â‹…
â‹…â‹…
â‹…
in)
Nut 7 N â‹…
â‹…â‹…
â‹…
m (0.7 kgf â‹…
â‹…â‹…
â‹…
m/61 lb â‹…
â‹…â‹…
â‹…
in)




RTW 47BMH000101
Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front
17. Install the front floor console and the rear floor
console.
18. Install the gear control lever knob.
To the female thread portion, apply 3 - 4 drops o
f
adhesive (TB1344 or LOCTITE 222 or equiv.) and
tighten the transmission knob.
Torque: 9 N â‹…
â‹…â‹…
â‹…
m (0.9 kgf â‹…
â‹…â‹…
â‹…
m/78 lb â‹…
â‹…â‹…
â‹…
in)
After tightening to specified torque, rewrench the knob until the direction of the shift pattern is in the
due positioned.
19. Connect the battery ground cable.


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MANUAL TRANSMISSION 7B1-17
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 speedometer sensor.
Remove the plate.
Remove the driven gear bushing and driven gear.
NOTE: Apply a reference mark to the driven gea
r
bushing before removal.
9. Remove the gear control box assembly.
10. Remove the rear cover assembly from the transmission case and intermediate plate.
11. Remove the intermediate plate with gear assembly from the transmission case.

Reassembly
1. Apply recommended liquid gasket (Three Bond
TB1215) or its equivalent to the transmission case,
intermediate plate and rear cover fitting surfaces.
2. Install the intermediate plate with the 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 main shaft to sudden shock o
r
stress.
3. Install the rear cover with an oil seal on the intermediate plate, with the 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 â‹…
â‹…â‹…
â‹…
m (3.8 kgf â‹…
â‹…â‹…
â‹…
m/27 lb â‹…
â‹…â‹…
â‹…
ft)
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 ne
w
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent, before
tightening.


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