2007 ISUZU KB P190 Speedometer

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

7B1-24 MANUAL TRANSMISSION
Reverse Gear and 5th Gear
Disassembled View
226R300027

Legend
(1) Bearing Snap Ring (11) Reverse Idler Gear Assembly
(2) Ball Bearing (12) Idle Shaft Pin
(3) Bearing Snap Ring (13) Thrust W asher
(4) Speedometer Drive Gear (14) Reverse Idler Gear
(5) Clip (15) Reverse Idler Shaft
(6) Retainer Snap Ring (16) Bearing Snap Ring
(7) Retainer (17) Ball Bearing
(8) Thrust Plate (18) Counter 5th Gear
(9) Thrust W asher and Lock Ball (19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring (20) 5th Gear

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ISUZU KB P190 2007

7B1-26 MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the bearing
snap ring.
2. Set the bearing remover 5-8840-2155-0 and the puller 5-8840-2027-0 to the bearing and the
mainshaft end, to remove the ball bearing.
262L100001
3. Remove the bearing snap ring, clip, speedometer
drive gear, retainer snap ring and the retainer.
4. Remove the thrust plate, thrust washer and lock ball.
5. Use a pair of snap ring pliers to remove the reverse idler gear snap ring.


226RS004

6. Remove the reverse idler gear assembly from the
intermediate plate.


226RS005
7. Remove the idle shaft pin, thrust washer, reverse idler gear, and reverse idler shaft.
8. Use a pair of snap ring pliers to remove the snap ring.
9. Attach a universal puller to the counter gear shaft. Use a universal puller to remove the ball bearing
and the counter 5th gear.


226RS006
10. Remove the counter reverse gear.



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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

7B1-16 Manual Transmission (MUX)
Transmission
Component
Legend1. Front case assembly with clutch housing
2. Front cover
3. Reverse switch
4. 1st switch
5. Reverse detent assembly
6. Neutral switch
7. Intermediate plate assembly
8. 5th detent assembly
9. Filler plug
10. Drain plug 11. Rear case assembly
12. End cover assembly (4x4 model) 13. Output shaft snap ring
14. Output rear bearing inner race
15. Speedometer driven gear
16. End cover assembly (4x2 model)
17. End cover gasket
18. Gear set clip
19. Speedometer drive gear
20. Straight plug
21. Dowel
22. Control rod detent assembly
23. Quadrant box

RTW77BLF001901
16
1718191314
1
23
22
20
12
13
14
2
3
4
5
6
21
21
11
10
9
8
7
15

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-19
b. Remove the taper bolt, and discard the usedtaper bolt.
c. Remove the control unit block.
7. Remove the reverse switch (Connector color Brown), 1st switch (Connector color Gray) and
neutral switch (Connector color Brown) with
gasket.
Remove the three detent assemblies, and discard
the used 5th & reverse detent assemblies.
8. Remove the two harness brackets.
9. Remove the speedometer driven gear and plate. (4x2 model)
10. Remove the end cover assembly. 11. Remove the gear set clip. (4x2 model)
12. Remove the speedometer drive gear. (4x2 model)
13. Stand the transmission assembly.
14. Remove the output shaft snap ring (1).
15. Remove the output rear bearing inner race (2).
16. Remove the rear case assembly (1). 17. Remove the magnet (2).
18. Remove the intermediate plate assembly with gear (1) from the front case.
19. Remove the tape from the spline portion of the input shaft.
20. Remove the front gutter (1) and rear gutter (3), and discard the used gutters.
RTW77BSH006001
RTW77BSH003901
2
1
RTW77BSH008101
1
2
RTW77BSH007501
1

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ISUZU KB P190 2007