torque ISUZU KB P190 2007 Workshop Repair Manual

7B1-6 Manual Transmission (MUX)
Fixing Torque
Legend

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(a) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(b) 19 N ⋅m (1.9 kgf ⋅m/14 lb ⋅ft)
(c) 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(d) 83 N ⋅m (8.5 kgf ⋅m/61 lb ⋅ft)
(e) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(f) 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(g) 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
(h) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(i) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(j) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft) (k) 30 N
⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
(l) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(m) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(n) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(o) 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
(p) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(q) 34 N ⋅m (3.5 kgf ⋅m/25 lb ⋅ft)
(r) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
(s) 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)

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ISUZU KB P190 2007

7B1-12 Manual Transmission (MUX)
22. Remove the transmission retaining nuts and bolts.Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.
23. Remove the transmission-transfer fixing bolts and nut, and disassemble the transfer from the
transmission. (4x4 model)
Installation
1. Apply grease (BESCO L-2 or equivalent) on the splined portion of the output shaft.
2. Connect the transfer to the transmission. (4x4 model)
3. Install the transmission-transfer fixing bolts and nut, and tighten them to the specified torque. (4x4
model)
Torque: 41 N ⋅m (4.2 kgf ⋅m/30 lb ⋅ft)
4. Apply a thin coat of molybdenum disulfide grease on the splined portion of the input shaft spline.
5. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the
engine.
6. Align the input shaft spline with the clutch driven plate spline.
7. Install the transmission assembly (4x2 model) or the transmission & transfer assembly (4x4 model)
to the engine.
• Tighten the transmission bolts to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
8. Apply a force 69 N ⋅m (7 kgf ⋅m/51 lb ⋅ft) to the tip of
the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.
Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N ⋅m (2.6 kgf ⋅m/19 lb ⋅ft). If
the shift fork will not move, then they are securely
engaged. 9. Connect harness clips on the transmission left
side.
10. Install the starter assembly.
• Tighten the starter bolts to the specified torque.
Torque: 94 N ⋅m (9.6 kgf ⋅m/69 lb ⋅ft)
11. Install the transmission rear mount to the transmission.
• Tighten the transmission rear mount bolts to the specified torque.
Torque: 50 N ⋅m (5.1 kgf ⋅m/37 lb ⋅ft)
12. Install the transmission crossmember by removing four bolts and nuts.
• Tighten the transmission crossmember bolts to the specified torque.
Torque: 67 N ⋅m (6.8 kgf ⋅m/49 lb ⋅ft)
13. Install the transmission rear mount nuts fixing on crossmember from transmission crossmember.
• Tighten the transmission rear mount nuts to the specified torque.
Torque: 52 N ⋅m (5.3 kgf ⋅m/38 lb ⋅ft)
Remove the transmission jack from transmission
side.
14. Install the fuel pipe bracket bolt and connect fuel pipe clip.
• Tighten the fuel pipe bracket bolt to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
15. Install the slave cylinder fixing bolts. • Tighten the slave cylinder bolts to the specifiedtorque.
Torque: 43 N ⋅m (4.4 kgf ⋅m/32 lb ⋅ft)
RTW77BSH007201

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-13
16. Install the front propeller shaft. (4x4 model)• Tighten the front propeller shaft bolts to thespecified torque.
Torque: 59 N ⋅m (6.0 kgf ⋅m/43 lb ⋅ft)
17. Install the rear propeller shaft.
• Tighten the rear propeller shaft bolts to thespecified torque.
Torque
Rear flange: 59 N ⋅m (6.0 kgf ⋅m/43 lb ⋅ft)
Center bearing: 69 N ⋅m (7.0 kgf ⋅m/51 lb ⋅ft)
18. Connect harness clip on the transmission left side bracket.
Install the harness bracket bolt.
• Tighten the harness bracket bolt to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft) 19. Connect the harness connectors and clips on the
transmission.
Legend 1. Neutral switch connector
2. Clutch damper valve connector

Legend 3. Clip
4. Reverse switch connector
5. 1st switch connector

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ISUZU KB P190 2007

7B1-14 Manual Transmission (MUX)
Legend6. Car speed sensor conector
7. Clip
8. 2-4 switch connector (4x4 model)
9. Neutral switch connector (4x4 model)
10. Transfer actuator connector (4x4 model)

20. Install the clutch housing cover and clutch bearing dust cover.
• Tighten the clutch housing cover bolts and clutch bearing dust cover bolts to the specified
torque.
Torque: 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
21. Install the gear control lever (1). • Tighten the gear control lever bolts to thespecified torque.
Torque: 19 N ⋅m (1.9 kgf ⋅m/14 lb ⋅ft)
22. Install the grommet assembly. • Tighten the grommet bolts to the specifiedtorque. Torque
Screw: 1.4 N ⋅m (0.14 kgf ⋅m/12 lb ⋅in)
Nut: 7 N ⋅m (0.7 kgf ⋅m/61 lb ⋅in)
Legend 1. Grommet Assembly
2. Floor Panel
3. Front

23. Install the front floor console. Refer to the section "Floor Console".
24. Install the rear floor console. (Bucket seat) Refer to the section "Floor Console".
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ISUZU KB P190 2007

7B1-28 Manual Transmission (MUX)
34. Install the shift rod (2) with the 1st-2nd shft block(3).
35. Install the 1st-2nd shift arm new spring pin. • Never reinstall the used spring pin.
Notice:
The spring pin must be drive in to this hole end surface
surfly.
36. Install the control rod assembly (1). 37. Install the shift & select rod assembly (1) and bolts
temporarily.
38. Install the shift rod bracket (1) and bolts temporarily.
39. Install the bolts to the shift & select rod assembly and shift rod bracket.
• Tighten the shift & select rod bolts and the shift rod bracket bolts to the specified torque.
Torque: 25 N ⋅m (2.5 kgf ⋅m/18 lb ⋅ft)
40. Install the counter 2nd gutter (4) and counter 5th gutter (2).
• Tighten the gutter bolts to the specified torque.
Torque: 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
41. Install the new front gutter (1) and new rear gutter (3).
• Never reinstall the used gutters.
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ISUZU KB P190 2007

7B1-30 Manual Transmission (MUX)
• Apply recommended liquid gasket (LOCTITEFMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.
Notice:
Be careful of the insertion position of the rear gutter.
47. Check whether the rear gutter (1) appears from the straight plug hole.
Install the new straight plug.
• Never reinstall the used straight plug.
• Tighten the straight plug to the specified torque.
Torque: 34 N ⋅m (3.5 kgf ⋅m/25 lb ⋅ft)
Notice: • If the rear gutter does not appear from the straight plug hole, the rear gutter is not in the right position.
Remove and reinstall the rear case.
• When there is no rear gutter in the right position, it becomes lubriciously poor. 48. Install the rear case bolts.
• Tighten the rear case bolts to the specifiedtorque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
49. Install the output rear bearing inner race.
50. Use the snap ring selector 5-8840-2849-0 to select the new output shaft snap ring.
• Never reinstall the used snap ring.
a. Place the snap ring selector on the output rear bearing.
b. Join the bolt (2) to the output shaft (4).
c. Adjust the end of both grips (3) with a bottom of spline and tighten both grips evenly.
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ISUZU KB P190 2007

7B1-32 Manual Transmission (MUX)
Snap Ring Availability51. Install the new snap ring to the output shaft. • Never reinstall the used snap ring.
52. Install the speedometer drive gear. (4x2 model)
53. Install the gear set clip. (4x2 model)
54. Install the end cover assembly.
• The gasket must be assembled. (4x2 model)
• 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. (4x4
model)
• Tighten the end cover bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
55. Install the speedometer driven gear and plate. (4x2 model)
56. Install the control rod detent assembly.
• Tighten the three detent assemblies to thespecified torque.
Torque: 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
57. Install the new 5th detent assembly and new reverse detent assembly.
• Never reinstall the used detent assembly.
• Tighten the three detent assemblies to the specified torque. Torque: 30 N
⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
58. Install the two harness brackets.
Torque: 8N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
59. Install the reverse switch (Connector color Brown), 1st switch (Connector color Gray) and neutral
switch (Connector color Brown) with gasket.
• Tighten the three switches to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
60. Install the control unit block by performing the following steps.
a. Push the control unit block ahead.
b. Install the control unit block.
c. Install the new taper bolt.
• Never reinstall the used taper bolt.
• Tighten the taper bolt to the specified torque.
Torque: 47 N ⋅m (4.8 kgf ⋅m/35 lb ⋅ft)
Important: • Must be checked no flaw to taper bolt.
• Must be checked no jam of foreign body before assembled.
• Must be checked same position upper surface of the taper bolt and the control unit block after
assembled.
61. Install the two dowels and quadrant box. • Apply recommended liquid gasket (LOCTITEFMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.
• Tighten the quadrant box bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
62. Remove the tape from the spline portion of the input shaft.
Thickness
Identification color
2.1 mm(0.083 in) White
2.2 mm(0.087 in) Blue
2.3 mm(0.091 in) Green
2.4 mm(0.094 in) Yellow
2.5 mm(0.098 in) Orange
2.6 mm(0.102 in) Black
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RTW77BSH005701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-33
63. Install the front cover.• Tighten the front cover bolts to the specifiedtorque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
64. After reassembling the transmission, refill the case with the new specified transmission oil.
a. Install the drain plug with new gasket. • Never reinstall the used gasket.
• Apply engine oil to the new gasket surface.
• Tighten the drain plug to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
b. Remove the filler plug with gasket.
c. Refill the case with the new specified transmission oil (BESCO Trans Axle Oil 5W-30
SF) amount 3.0 liters.
d. Install the filler plug with new gasket. • Never reinstall the used gasket.
• Apply engine oil to the new gasket surface.
• Tighten the filler plug to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-35
4. Use the installer 5-8840-0125-0 (2) and grip 5-8840-0007-0 (1) to remove the front oil seal and
input shaft needle bearing from the front case, and
discard the used oil seal.
Installation
1. Use the installer 5-8840-2846-0 (2) and grip 5- 8840-0007-0 (1) to install the input shaft needle
bearing to the front case.
Notice:
Please install by making a stamp side into rear.
2. Install the front oil seal. a. Use the installer 5-8840-2846-0 (2) and grip 5- 8840-0007-0 (1) to install the new front oil seal
to the front case.
• Never reinstall the used oil seal.
• Apply engine oil to new front oil seal outer surfaces, and apply grease (BESCO L-2 or
equivalent) to the oil seal lip. • At press fitting the oil seal, to be careful not
to inflict lip of it.
b. The oil seal must be pressed fit as shown in the figure.
Legend 1. Front oil seal
2. 4 mm (0.157 in)
3. Front case

3. Install the reverse idler shaft with straight pin.
4. Install the reverse idler gear assembly and reverse shaft bracket.
• Apply engine oil to gear internal surface.
5. Install the reverse idler bolt with gasket.
• Tighten the reverse idler bolt to the specifiedtorque.
Torque: 83 N ⋅m (8.5 kgf ⋅m/61 lb ⋅ft)
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ISUZU KB P190 2007

7B1-54 Manual Transmission (MUX)
4. Install the straight pin.
5. Install the reverse inhibitor bolt.
• Tighten the reverse inhibitor bolt to thespecified torque.
Torque: 36 N ⋅m (3.7 kgf ⋅m/27 lb ⋅ft)
6. Install the reverse inhibitor and spring.
7. Install the new reverse inhibitor snap ring.
• Never reinstall the used snap ring.
Notice:
The snap ring must be assembled in groove of bolt
surely.
RTW77BSH002701
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ISUZU KB P190 2007