2007 ISUZU KB P190 torque

7B1-102 MANUAL TRANSMISSION
Torque Specifications
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



RTW 77BLF003801
About arrow mark, refer to Transmission (MUA) Installation in this section.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-103
Torque Specifications (Cont'd)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)







RTW 77BLF003901


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ISUZU KB P190 2007

7B1-104 MANUAL TRANSMISSION
Torque Specifications (Cont'd)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



RTW 57BLF000301


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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-1
TRANSMISSION/TRANSAXLE
Manual Transmission(MUX)
TABLE OF CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . 7B1-2 General Description . . . . . . . . . . . . . . . . . . . . . 7B1-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7B1-4
Main Specifications . . . . . . . . . . . . . . . . . . . . . 7B1-5
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-6
Transmission Assembly . . . . . . . . . . . . . . . . . . . 7B1-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-12
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-16 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-18
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-24
Front Case Assembly . . . . . . . . . . . . . . . . . . . . 7B1-34 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-35
Rear Case Assembly . . . . . . . . . . . . . . . . . . . . 7B1-36 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-37
End Cover Assembly. . . . . . . . . . . . . . . . . . . . . 7B1-39 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . 7B1-40 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-40
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-41
Counter Shaft Assembly . . . . . . . . . . . . . . . . . . 7B1-43 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-43
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-47
Output Shaft Assembly . . . . . . . . . . . . . . . . . . . 7B1-50 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Shift & Select Rod Assembly . . . . . . . . . . . . . . 7B1-51 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Intermediate Plate Assembly . . . . . . . . . . . . . . 7B1-53 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Control Rod Assembly . . . . . . . . . . . . . . . . . . . 7B1-55 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55
5th-Reverse Shift Block Assembly . . . . . . . . . . 7B1-56 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
3rd-4th Shift Arm Assembly. . . . . . . . . . . . . . . . 7B1-57 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-58 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-58

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ISUZU KB P190 2007

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

RTW77BLF001701
b
a
r
q
p
s
c
d
f
eg
h
i
j
l
k
mn
o
(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

RTW77BSH000301
RTW77BSH006601
1
2
RTW77BSH006701
3
3 54

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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".
RTW77BSH006801
10 9
6
7 8
7
RTW77BSH007101
1
RTW77BMH000101
1
2
3

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