2007 ISUZU KB P190 oil

7B-40 MSG MODEL
MAJOR COMPONENTS









RTW 47BLF000401

Reassembly steps
1. Intermediate plate with gear assembly

2. Rear cover with oil seal

3. Transmission case

4. Bearing snap ring
5. Counter gear snap ring



6. Front cover with oil seal
7. Speedometer driven gear
8. Gear control box assembly
9. Speedometer sensor
10. Clutch shift fork
11. Clutch shift block and release bearing



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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

7B-42 MSG MODEL
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

9-8529-2201-0
Spring pin remover
5-8840-0013-0
(J-22888) Gear remover
5-8840-2001-0
(J-29768) Holding fixture

5-8840-0353-0
(J-36629) Lock nut wrench
5-8840-0015-0
(J-22912-01) Bearing remover/installer
5-8840-0026-0
(J-26540) Oil seal installer

5-8522-0050-0
(J-29769) Oil seal installer

5-8840-0178-0
(J-33851) Collar installer


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-1
SECTION 7B1
MANUAL TRANSMISSION
(MUA)
TABLE OF CONTENTS
PAGE
MUA5G/5H/5S (4 ×
××
×
2)
Service Precaution ......................................................................................................... 7B 1 – 3
General Description ........................................................................................................ 7B 1 – 4
Rear Oil Seal ................................................................................................................. .. 7B1 – 5
Transmission (4 ×
××
×
2) ......................................................................................................... 7B1 – 7
Disassembled View..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –11
Transmission Case .......................................................................................................... 7B1 –16
Major Component........................................................................................................ 7B1 –16
Disassembly ................................................................................................................ 7B1 –17
Reassembly ................................................................................................................. 7B1 –17
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –20
Disassembled View..................................................................................................... 7B1 –20
Disassembly ................................................................................................................ 7B1 –21
Inspection and Repair................................................................................................. 7B1 –22
Reassembly ................................................................................................................. 7B1 –23
Reverse Gear and 5th Gear ............................................................................................ 7B1 –24 Disassembled View..................................................................................................... 7B1 –24
Disassembly ................................................................................................................ 7B1 –26
Inspection and Repair................................................................................................. 7B1 –28
Reassembly ................................................................................................................. 7B1 –28
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –34 Disassembled View..................................................................................................... 7B1 –34
Disassembly ................................................................................................................ 7B1 –36
Inspection and Repair................................................................................................. 7B1 –38
Reassembly ................................................................................................................. 7B1 –41
Main Data and Specifications ......................................................................................... 7B1 –47

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MANUAL TRANSMISSION 7B1-5
Rear Oil Seal
Disassembled View
220R300030
Legend
(1) Rear Propeller Shaft (2) Rear Oil Seal

Removal
1. Raise and support the vehicle with suitable jack
stands.
2. Remove the propeller shaft flange yoke bolts and nuts at the differential side.
3. Remove center bearing from the crossmember.
4. Remove prepeller shaft from the transmission main shaft spline.
Refer to the section “Rear Propeller Shaft”.
5. Use a screwdriver to pry the rear oil seal from the rear cover.

Installation
1. Install a new oil seal using the installer 5-8522-0050- 0.



220RS044
2. Insert the splined yoke into the transimission
mainshaft spline.
3. Install the propeller shaft flange yoke to the drive pinion flange.

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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

MANUAL TRANSMISSION 7B1-17
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 speedometer sensor.
Remove the plate.
Remove the driven gear bushing and driven gear.
NOTE: Apply a reference mark to the driven gea
r
bushing before removal.
9. Remove the gear control box assembly.
10. Remove the rear cover assembly from the transmission case and intermediate plate.
11. Remove the intermediate plate with gear assembly from the transmission case.

Reassembly
1. Apply recommended liquid gasket (Three Bond
TB1215) or its equivalent to the transmission case,
intermediate plate and rear cover fitting surfaces.
2. Install the intermediate plate with the 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 main shaft to sudden shock o
r
stress.
3. Install the rear cover with an oil seal on the intermediate plate, with the 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)
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 ne
w
bolt, dry it thoroughly.
Apply recommended liquid
gasket (LOCTITE 242) or its equivalent, before
tightening.


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ISUZU KB P190 2007

7B1-18 MANUAL TRANSMISSION
4. Install a new gasket and gear control box assembly.
Install the harness clips and brackets and then
tighten 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 O-ring (3) to the speedometer driven gear
bushing (2).
Install the driven gear to the speedometer driven gear bushing (2).
6. Install the speedometer driven gear assembly to the transmission rear cover.
Install the plate (1) to the transmission rear cover.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
7. Install the speedometer sensor.
Torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kgf ⋅
⋅⋅
⋅
m/20 lb ⋅
⋅⋅
⋅
ft)



RTW 77BSH008501
8. Install top gear bearing snap ring and counter 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.
9. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to a new oil seal, on the oute
r
circumference.
• 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.
220R3000020
10. 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