2007 ISUZU KB P190 lock

MANUAL TRANSMISSION 7B1-81
11. Remove the 5th gear, 5th block ring, and needle
bearing (2 piece type).


226RS007
12. Remove the mainshaft nut according to following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counte
r
gear.
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• Engage the 3rd-4th synchronizer with the 3rd
gear.
• Engage the 1st-2nd synchronizer with the 1st
gear.

226RW 210
•
Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut.
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ISUZU KB P190 2007

7B1-82 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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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-83
2. Install the bearing snap ring.
3.
Apply recommended thread locking agents
(LOCTITE 242) or 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)

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4. Install the needle bearing, reverse gear and reverse block ring. 5. Assemble the 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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ISUZU KB P190 2007

7B1-84 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)
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8. Use a punch to stake the mainshaft nut.


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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.


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ISUZU KB P190 2007

7B1-86 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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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-87

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. Apply engine oil to the bearing inner and oute
r
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
18.
Apply engine oil to the oil seal collar inner
circumference.
Install the oil seal collar to the mainshaft by using
the installer 5-8840-2159-0.
19. Install the oil seal collar snap ring.




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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-89
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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ISUZU KB P190 2007

7B1-90 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.
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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.
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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
the needle bearing collar.
226RW 218




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ISUZU KB P190 2007