2007 ISUZU KB P190 indicator

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

7B1-94 MANUAL TRANSMISSION
Mainshaft Run-out
• Install the mainshaft to V-blocks.
• Use a dial indicator to measure the mainshaft
central portion run-out.


226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter
• Use an inside dial indicator to measure the gear
inside diameter.


226RS040
If the measured value is less than the specified limit,
the gear must be replaced.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
• Use a micrometer to measure the idler gear shaft
diameter.
• Use an inside dial indicator to measure the idle
r
gear inside diameter.

226RS041
• Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-95
Clutch Hub Spline Play
• Set a dial indicator to the clutch hub which requires
measuring.


226RS042
• Move the clutch hub as far as possible to the right
and left.
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 the 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 the bearing installer 5-8840-2194-0 to install
the front roller bearing inner race to the counte
r
gear 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

Manual Transmission (MUX) 7B1-23
Block Ring and Insert Clearance
Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and insert.
If the measured value exceeds the specified limit, the
block ring and insert must be replaced.
Clutch Hub and Insert Clearance
Use a thickness gauge to measure the clearance
between the clutch hub and insert.
If the measured value exceeds the specified limit, the
clutch hub and insert must be replaced. Gear Inside Diameter
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit,
the gear must be replaced.
Standard
Limit
3rd - 4th 5th 3.59 - 3.91 mm
(0.141 - 0.154 in) 4.10 mm
(0.161 in)
LNW25CSH028401
RTW77BSH006501
Standard Limit
3rd - 4th 5th 0.09 - 0.31 mm
(0.004 - 0.012 in) 0.40 mm
(0.016 in)
Standard Limit
3rd 45.000 - 45.016 mm
(1.7717 - 1.7723 in) 45.056 mm
(1.7739 in)
5th 48.000 - 48.016 mm
(1.8898 - 1.8904 in) 48.056 mm
(1.8920 in)
LNW25CSH028701
LNW25CSH028901

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ISUZU KB P190 2007

7B1-24 Manual Transmission (MUX)
Clutch Hub Spline Play• Set a dial indicator to the clutch hub to be measured.
• Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Counter Gear Spline Play
Refer to Counter Shaft Assembly in this section.
Installation
1. Use a pair of snap ring pliers to hold the new input middle bearing snap ring open .
Install the input shaft assembly to the intermediate
plate.
• Never reinstall the used snap ring.
2. Install the input middle bearing snap ring.
3. Install the 5th input gear needle bearing. (2 piece type)
4. Install the 5th input gear assembly. • Apply engine oil to the gear internal surface.
5. Assemble the 5th synchronizer assembly by performing the following steps.
• Turn the clutch hub face (2) toward the sleeve groove (1) (rear side) on the outer
circumference. • Check that the inserts (3) fit snugly into the
clutch hub (6) ring insert grooves.
• Check that the inserts springs (4) are fitted to the inserts as shown in the figure.
• Check that the clutch hub (6) and the sleeve (5) slide smoothly.
• The insert springs (4) must be set in such a way that the opening of spring faces different
direction.
6. Install the 5th block ring and 5th synchronizer assembly.
7. Install the new 5th hub snap ring (1).
• Never reinstall the used snap ring.
• Choose the thickest snap ring among ones whitch can be assembled.
Snap Ring Availability
Standard
Limit
3rd - 4th 0.010 - 0.102 mm
(0.0004 - 0.0040 in) 0.15 mm
(0.0059 in)
5th 0.009 - 0.104 mm
(0.0004 - 0.0041 in) 0.15 mm
(0.0059 in)
LNW25CSH029101
Thickness Identification color
1.95 mm(0.077 in) No color
2.10 mm(0.083 in) Yellow
1
2
LNW25CSH025601
3 45
6
LNW25CSH025701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-41
2. Use a bench press to remove the 5th input collarand input middle bearing from the input shaft.
3. Remove the oil catch impeller from the input shaft.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage or any other abnormal conditions are
found through inspection.
Input Shaft Run-out • Install the input shaft to V-blocks.
• Use a dial indicator to measure the input shaft central portion run-out.
If the measured input shaft run-out exceeds the
specified limit, the input shaft must be replaced. Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Installation
1. Install the oil catch impeller (1) to the input shaft.
Notice:
Direction of assembling exists. (Groove opening area
to be bearing side.)
Limit
0.05 mm
(0.002 in)
RTW75CSH000201
Standard Limit
0 - 0.066 mm
(0 - 0.0026 in) 0.1 mm
(0.004 in)
RTW77BSH002301
LNW25CSH029201

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-45
1st-2nd Synchronizer (3-CONE)
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the
1st-2nd synchronizer assembly must be replaced.
Block Ring and Insert Clearance
Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and insert.
If the measured value exceeds the specified limit, the
block ring and insert must be replaced. Clutch Hub and Insert Clearance
Use a thickness gauge to measure the clearance
between the clutch hub and insert.
If the measured value exceeds the specified limit, the
clutch hub and insert must be replaced.
Counter Shaft Run-out • Install the counter shaft to V-blocks.
• Use a dial indicator to measure the counter shaft central portion run-out.
If the measured counter shaft run-out exceeds the
specified limit, the counter shaft must be replaced.
Standard Limit
1.5 mm
(0.059 in) 0.8 mm
(0.031 in)
Standard Limit
1st - 2nd 3.86 - 4.16 mm
(0.152 - 0.164 in) 4.4 mm
(0.173 in)
Reverse 2.16 - 2.46 mm
(0.085 - 0.097 in) 2.7 mm
(0.106 in)
LNW25CSH028501
Standard Limit
1st - 2nd Reverse 0.01 - 0.21 mm
(0.0004 - 0.0083 in) 0.3 mm
(0.0118 in)
RTW77BSH006501
LNW25CSH028701

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ISUZU KB P190 2007

7B1-46 Manual Transmission (MUX)
Gear Inside Diameter
Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit,
the gear must be replaced. Clutch Hub Spline Play
• Set a dial indicator to the clutch hub to be measured.
• Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Counter Gear Spline Play
• Set a dial indicator to the gear to be measured.
• Move the gear as far as possible to both the right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the
gear must be replaced.
Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit
0.05 mm
(0.002 in)
Standard Limit
1st
2nd 53.000 - 53.019 mm
(2.0866 - 2.0874 in) 53.059 mm
(2.0889 in)
Reverse 42.000 - 42.019 mm
(1.6535 - 1.6543 in) 42.059 mm
(1.6559 in)
RTW77BSH002401
LNW25CSH028901
Standard Limit
1st - 2nd 0 - 0.04 mm
(0 - 0.0016 in) 0.10 mm
(0.0039 in)
Reverse 0 - 0.107 mm
(0 - 0.0042 in) 0.15 mm
(0.0059 in)
Standard Limit
3rd 5th
Output 0.013 - 0.121 mm
(0.0005 - 0.0048 in) 0.15 mm
(0.0059 in)
LNW25CSH029101

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ISUZU KB P190 2007