2007 ISUZU KB P190 oil

MANUAL TRANSMISSION 7B1-23
Reassembly
1. Install the rev-5th shift arm and reverse inhibitor and
the 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 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 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

7B1-30 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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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-31
11. Install the counter 5th gear to the counter shaft.


226RS019
12. Install the ball bearing and bearing snap ring by
performing the following steps:
• Select the snap ring which will provide the
minimum clearance between the ball bearing
and the snap ring.


226RS020

• There are six snap ring sizes available.
The snap rings are color‐coded to indicate
their thickness.


226RS021
Ball Bearing and Snap Ring Clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in)
Snap Ring Availability
Thickness Color Coding
1.1 mm (0.043 in) W hite
1.2 mm (0.047 in) Yellow
1.3 mm (0.051 in) Blue
1.4 mm (0.055 in) Pink
1.5 mm (0.059 in) Green
1.6 mm (0.063 in) Brown
• Use a pair of snap ring pliers to install the snap
ring to the counter gear shaft.
The snap ring must be fully inserted into the
counter gear shaft snap ring groove.
13.
Assemble the reverse idler shaft, reverse idler gear,
thrust washer, and idle shaft pin into the reverse
idler gear assembly.
The thrust washer should be assembled with the oil
groove faces to gear side.



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-33

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. Install the retainer snap ring, clip, speedometer drive gear and bearing snap ring.
18.
Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
19. Install the bearing snap ring.




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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-41
Clutch Hub Spline Play
• Set a dial indicator to the clutch hub which requires
measuring.


226RS042
• Move the clutch hub as far to the right and left as
possible.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd 3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
• Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)



226RS043

Reassembly
1. Install the center roller bearing to counter gear shaft.
•
Apply engine oil to the bearing inner and outer
circumferences.
• Install the roller bearing in the proper direction.
NOTE: Check that the outer race moves only in the
direction of the arrow.


226RS044
2. Install the front roller bearing by performing the following steps.
• Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gea
r
shaft.
• Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.



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ISUZU KB P190 2007

7B1-42 MANUAL TRANSMISSION
• Use bearing installer 5-8840-2194-0 to install the
ring.



RTW 57BSH000101
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install the bearing snap ring to the counter gear
shaft.
4.
Apply engine oil to the needle bearing and the 2nd
gear thrust surfaces.
Install the needle bearing and the 2nd gear to the
mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.


226RS046

5. Assemble the 2nd inside ring, 2nd outside ring, and
2nd block ring on the 2nd gear.
•
Apply engine oil to the synchronizer ring friction
surfaces.


226RS047
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing



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ISUZU KB P190 2007

7B1-44 MANUAL TRANSMISSION

226RS031
9. Install the needle bearing, 1st block ring, 1st outside
ring , 1st inside ring, and 1st gear.
•
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
• The 1st gear dog teeth must be facing the
transmission front side.


226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
10. Install the 1st gear thrust bearing and the race to the
main shaft.
The thrust bearing side must be facing the
transmission front side.


226RS054
11. Apply engine oil to the mainshaft ball bearing and the mainshaft.
Install the ball bearing and needle bearing collar to
the mainshaft.
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.


226RS055



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-45
12. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing and the 3rd gear to the
mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.


226RS056
13. Install the 3rd block ring.
14. Check and install the 3rd-4th synchronizer assembl
y
using the following steps:
1. Check that the inserts (3) fit snugly into the clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the inserts, as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be facing the 3rd gear side.


226RS049

226RW 221
15. Select and install mainshaft snap ring using the
following instructions:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.


226RS058
There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness as shown in the figure.


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ISUZU KB P190 2007