2007 ISUZU KB P190 check oil

MANUAL TRANSMISSION 7B1-51
TROUBLESHOOTING
1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper gear
oil
NG
Mainshaft splines
Synchronizer clutch hub
splinesReplace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
W orn splines
W orn or scuffed gear tooth
contact surfaces
Flywheel pilot bearingW orn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)W orn or broken bearing(s)
OK NG
NG
NG
NG
OK
OK
OK
Gear oil
TransmissionRealign the transmissionTransmission misalignment
OK
NG



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ISUZU KB P190 2007

7B1-52 MANUAL TRANSMISSION
2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil
NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)W orn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)W orn, chipped, or cracked
gear(s)
NG
NG
NG
NG
OK
OK
OK
OK
Gear oil (Metallic rattling)



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-53
2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
W orn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OK NG
NG
NG
NG
OK
OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxW orn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG
NG
OKShift block sleeve movement


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-57
4. OIL LEAKAGE

Checkpoint Trouble Cause Countermeasure

Gear oilReplace the gear oilImproper gear oil
Drain plug and/or filler plugTighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OK NG
NG
NG
OK
OKOil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
W orn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil sealReplace the oil seal
Replace the gasket(s)
W orn or scratched oil seal
Defective or improperly
installed gasket(s)
OK NG
NG
NG
NG
OK
OKGaskets



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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 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

MANUAL TRANSMISSION 7B1-105
TROUBLESHOOTING
1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper gear
oil
NG
Mainshaft splines
Synchronizer clutch hub
splinesReplace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
W orn splines
W orn or scuffed gear tooth
contact surfaces
Flywheel pilot bearingW orn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)W orn or broken bearing(s)
OK NG
NG
NG
NG
OK
OK
OK
Gear oil
TransmissionRealign the transmissionTransmission misalignment
OK
NG



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ISUZU KB P190 2007

7B1-106 MANUAL TRANSMISSION
2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper engine
oil
NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the inner
face
Bearings (Hissing, thumping
or bumping)W orn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)W orn, chipped, or cracked
gear(s)
NG
NG
NG
NG
OK
OK
OK
OK
Gear oil (Metallic rattling)



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ISUZU KB P190 2007