2007 ISUZU KB P190 torque

7B1-66 MANUAL TRANSMISSION
Installation
1. Apply grease (BESCO L2 or equivalent) on the
splined portion of the output shaft.
2. Connect the transfer to the transmission.
3. Install the transmission-transfer bolts and nut and tighten them to the specified torque.
Torque: 41 N ⋅
⋅⋅
⋅
m (4.2 kgf ⋅
⋅⋅
⋅
m/30 lb ⋅
⋅⋅
⋅
ft)
mm (in)



RTW 77BMF001501

4. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
5. Slowly operate the transmission jack until the front of the transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must be the same.
6.
Align the top gear shaft with the clutch driven plate
spline.
7. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts, as shown in
the figure.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-69
8. Install the starter. (Diesel engine)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
9. Install the rear support rubber on the transmission and tighten the bolts to the specified torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
10. Install the middle part of transmission crossmember and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
11. Install the engine rear mount nuts.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from the
transmission side.
12. Apply grease to top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
13. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe brackets
Torque: Bolt & Nut 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
Nut 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
Diesel engine
220R300012

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





C24SE
Scan-2
14. Connect the transmission harness connectors and
clips. Connector: transfer neutral switch, 2W D -
4W D switch, actuator, car speed sensor, backup
switch, transmission neutral switch.
810R300069
Legend
(1) Neutral Switch Connector: Transmission
(2) Backup Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W D - 4W D Switch connector
(6) Neutral Switch Connector: Transfer


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ISUZU KB P190 2007

7B1-70 MANUAL TRANSMISSION
15. Tighten the exhaust pipe fixing nuts to the specified
torque. (Diesel engine only)
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)







RTW 67BSH000101
16. Install the front propeller shaft.
Refer to the section “Front Propeller Shaft”.
17. Install the rear propeller shaft.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
18. Install the center bearing on crossmember.
Torque: 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅
⋅⋅
⋅
m/51 lb ⋅
⋅⋅
⋅
ft)
19. Install the gear control lever.
Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
20. Install the grommet assembly.
Torque: Screw 1.4 N ⋅
⋅⋅
⋅
m (0.14 kgf ⋅
⋅⋅
⋅
m/12 lb ⋅
⋅⋅
⋅
in)
Nut 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)





RTW 47BMH000101
Legend
(1) Grommet Assembly
(2) Floor Panel
(3) Front
21. Install the front floor console and rear floor console.
22. 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 ⋅
⋅⋅
⋅
m (0.9 kgf ⋅
⋅⋅
⋅
m/78 lb ⋅
⋅⋅
⋅
in)
After tightening to specified torque, rewrench the
knob until the direction of the shift pattern is in the
due position.
23. Connect the battery ground cable.



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ISUZU KB P190 2007

7B1-72 MANUAL TRANSMISSION
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 gear control box assembly.
9. Remove the rear case assembly from the transmission case and intermediate plate.
10. Remove the intermediate plate with gear assembl
y
from the transmission case.

Rear Oil Seal Replacement
220R300025

Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard the used oil seal.
2. Apply engine oil to the new oil seal outer surfaces.
3.
Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 5- 8840-0007-0 to install the oil seal to the rear case.
Reassembly
1. Apply recommended liquid gasket (Three Bond TB1215) or its equivalent to the transmission case,
intermediate plate and rear case fitting surfaces.
2. Install the intermediate plate with 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 mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal on the intermediate plate, with 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 ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-73
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 new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
4. Install a new gasket and gear control box assembly. Install the harness clips and brackets and then
tighten the four new gear control box bolts to the
specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
261R300004
5. Install the top gear bearing snap ring and counte
r
front bearing snap ring.
• Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
• The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to the outer circumference o
f
new oil seal.
• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R300002
7. Install a new gasket and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
• After cleaning the bolt hole, air dry it thoroughly.
•
After cleaning the screw face of a removed or new
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
Tighten the six front cover bolts to the specified
torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.6 kgf ⋅
⋅⋅
⋅
m/19 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

7B1-78 MANUAL TRANSMISSION
Reassembly
1. Install the rev-5th shift arm and reverse inhibitor and
rev-5th shift rod.
• Apply oil to the reverse inhibitor inner surface.
• Install the shift rod in the intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.
• Install the interlock pin in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
2. Install the 1st-2nd shift arm and 3rd-4th shift arm to the intermediate plate and gear assembly.
3. Install the 3rd-4th shift rod and the 1st-2nd shift rod. • Install the interlock pin in the intermediate plate
and gear assembly.
• Install the 3rd-4th shift rod in the intermediate
plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Install the interlock pin and then the 1st-2nd shift
rod in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.


230RS007
4. Install the spring.
5. Put the detent balls in the intermediate plate holes.• Apply oil to the detent balls.
6. Install the detent springs and detent spring plate and gasket.
NOTE: For South Africa model, it has double detent
spring for Rev-5th shift rod.
• Install a new gasket and the detent spring plate.
• Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)


220RS030
Legend
(1) W arped



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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)

220RW 137
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)
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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