2007 ISUZU KB P190 Engine

7B1-72 MANUAL TRANSMISSION
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 gear control box assembly.
9. Remove the rear case assembly from the transmission case and intermediate plate.
10. Remove the intermediate plate with gear assembl
y
from the transmission case.

Rear Oil Seal Replacement
220R300025

Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard the used oil seal.
2. Apply engine oil to the new oil seal outer surfaces.
3.
Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 5- 8840-0007-0 to install the oil seal to the rear case.
Reassembly
1. Apply recommended liquid gasket (Three Bond TB1215) or its equivalent to the transmission case,
intermediate plate and rear case fitting surfaces.
2. Install the intermediate plate with 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 mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal on the intermediate plate, with 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)


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-73
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 new
bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.
4. Install a new gasket and gear control box assembly. Install the harness clips and brackets and then
tighten the 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 top gear bearing snap ring and counte
r
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.
6. Front cover with oil seal. Front Cover Oil Seal Replacement • Remove the oil seal from the front cover.
• Apply engine oil to the outer circumference o
f
new oil seal.
• 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.
220R300002
7. 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

7B1-84 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 7B1-87

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. Apply engine oil to the bearing inner and oute
r
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing to the mainshaft.
226L100002
18.
Apply engine oil to the oil seal collar inner
circumference.
Install the oil seal collar to the mainshaft by using
the installer 5-8840-2159-0.
19. Install the oil seal collar snap ring.




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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

7B1-96 MANUAL TRANSMISSION
• Use the 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
the 2nd block ring.
•
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

7B1-98 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 7B1-99
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
by 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