2007 ISUZU KB P190 engine oil

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 N⋅m(kgf ⋅m/lb ⋅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

7B-28 MSG MODEL


BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play mm(in)
Limit
0.2 (0.0079)



FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.





Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer : 5-8840-0026-0 (J-26540)
2. Apply engine oil to the oil seal lip.



REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.





Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the rear cover.
Oil Seal Installer : 5-8522-0050-0 (J-29769)
2. Apply engine oil to the oil seal lip.



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ISUZU KB P190 2007

MSG MODEL 7B-31




Important Operations
2. Needle Bearing
3. 2nd Gear
1) Apply the engine oil to the 2nd needle bearing and the 2nd gear.
2) Install the needle bearing and the 2nd gear to the mainshaft.
The dog teeth of the 2nd gear must be facing the rear side of the transmission.


5. 1st-2nd Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The outside sleeve heavy chamfering must be facing the rear of the transmission.
1 Chamfer Angle = 30 °
2 Chamfer Angle = 45 °



7. Needle Bearing Collar
Use a bench press and a collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)



8. Needle Bearing
9. 1st Gear
1) Apply the engine oil to the 1st needle bearing and the 1st
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 1st gear must be facing the front side of the transmission.


10. 1st Gear Thrust Washer
Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the 1st gear side.


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ISUZU KB P190 2007

7B-32 MSG MODEL




11. Mainshaft Ball Bearing
1) Apply the engine oil to the ball bearing inside circumference.
2) Use a bench press and a bearing installer to install the bearing.
The bearing snap ring groove must be facing the front o
f
the transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)





12. Needle Bearing
13. 3rd Gear
1) Apply the engine oil to the 3rd needle bearing and the 3rd
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 3rd gear must be facing the front side of the transmission.






15. 3rd-4th Synchronizer Assembly
1)
Apply the recommended lubricating oil to the clutch hub
spline.
2) Install the synchronizer assembly to the mainshaft.
The sleeve light chamfering
1 and the clutch hub heavy
boss
2 must be facing the rear of the transmission.




16. Mainshaft Snap Ring
1) Select the snap ring which will provide the minimum clearance between the mainshaft and the snap ring.
There are four snap ring sizes available.
The snap rings are numbered to indicate their thickness.
Mainshaft and Snap Ring Clearance mm(in)
Standard
0 - 0.05 (0 - 0.002)


Snap Ring Availability
mm(in)
Thickness Identification Number
1.50 (0.059) 1
1.55 (0.061)2
1.60 (0.063)3
1.65 (0.065)4
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.

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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

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 N⋅m(kgf ⋅m/lb ⋅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 N⋅m(kgf ⋅m/lb ⋅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

7B1-16 MANUAL TRANSMISSION
Transmission Case
Major Component






RTW 77BLF003301
Legend
(1) Gear Control Box Assembly and Gasket (7) Shift Fork and Cover: Diesel engine
(2) Speedometer Sensor and Driven Gear (8) Counter Front Bearing Snap Ring
(3) Rear Cover Assembly (9) Front Cover (with Oil Seal)
(4) Intermediate Plate with Gear Assembly (10) Top Gear Bearing Snap Ring
(5) Transmission Case (11) Release Bearing: C24SE
(6) Release Bearing (with Spring) : Diesel engine (12) Shift Fork: C24SE



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ISUZU KB P190 2007