2007 ISUZU KB P190 check oil

MANUAL TRANSMISSION 7B1-107
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 7B1-111
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

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) 7B1-25
8. Install the counter middle roller bearing outer race,counter shaft assembly and 5th counter gear to the
intermediate plate.
• Apply engine oil to the gear internal surface.
9. Install the 3rd counter gear. • Apply engine oil to the gear internal surface.
10. Iinstall the 3rd input gear needle bearing.
11. Assemble the 3rd-4th 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. 12. Install the 3rd input gear assembly, 3rd-4th block
ring of 3rd input gear side, and 3rd-4th
synchronizer assembly.
• Apply engine oil to the gear internal surface.
13. Install the new 3rd-4th hub snap ring (1).
• Never reinstall the used snap ring.
• Choose the thickest snap ring among ones whitch can be assembled.
Snap Ring Availability
RTW77BSH005101
1
Thickness Identification color
1.9 mm(0.075 in) No color
2.1 mm(0.083 in) Yellow
2.3 mm(0.091 in) Pink
1
2
LNW25CSH025601
3 45
6
LNW25CSH025701

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ISUZU KB P190 2007

Manual Transmission (MUX) 7B1-47
Installation
1. Install the needle bearing, 2nd counter gearassembly, 2nd inside ring, 2nd outside ring, and
2nd block ring.
• Apply engine oil to the needle bearing and gear internal surface.
2. Assemble the 1st-2nd synchronizer assembly by performing the following steps.
• Check that the inserts (1) fit snugly into the clutch hub (4) insert grooves.
• Check that the inserts springs (2) are fitted to the inserts as shown in the figure.
• Check that the clutch hub (4) and sleeve (3) slide smoothly.
• The insert springs (2) must be set in such a way that the opening of each spring faces different
direction. 3. Use a bench press and installer 9-8522-1182-0 (1)
to install the 1st-2nd synchronizer assembly, 1st
block ring, 1st outside ring and 1st inside ring.
• Apply engine oil to the block ring internal surface.
4. Install the needle bearing and 1st counter gear assembly.
• Apply engine oil to the needle bearing and gear internal surface.
5. Use a bench press and installer 9-8522-1182-0 (1) to install the 1st counter collar.
Notice:
The collar must be press fitted with end surface of
sleeve & hub.
Standard
Limit
Front 0 - 0.098 mm
(0 - 0.0039 in) 0.15 mm
(0.0059 in)
LNW25CSH029201
LNW45CSH002301
1
23
4
RTW75CSH000901
1

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ISUZU KB P190 2007

CLUTCH 7C-29

RTW 77CSH000301
Release Bearing (MUX)
1. Visually check the release bearing for excessive play, noiseand breakage.
2. If any of these conditions are discovered, the release bearing must be replaced.
3.
Apply molybdenum disulfide grease to the areas shown in
illustration.
201RW 010-X
4. W hen replacing the release bearing (3), replace both the
wedge collar (2) and wire ring (1) at the same time.
201RS013
Wedge Collar
1. Visually check the surfaces of the wedge collar makingcontact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear or damage.

RTW 77CSH000701
Shift Fork
1. Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from shift fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.
4.
Apply molybdenum disulfide grease to the pin hole inner
circumferences and thrust surfaces.



RTW 57CSH000401

Release Bearing (MSG, MUA)
1. Visually inspect the surfaces of the release bearing making contact with the shift fork for excessive wear and damage.
Replace any exhibiting excessive wear or damage.
2. Apply multi-purpose type grease (NLGI No.2 or No.3) to contact surface between the release bearing and the shift
fork. (Do not apply grease to the sleeve inner face.)


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ISUZU KB P190 2007

7C-30 CLUTCH


RTW 57CSH000201

Shift Fork
1. Visually inspect the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from the release bearing with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.





RTW 57CSH000501




DRIVEN PLATE ASSEMBLY
1. Visually inspect the torsion spring 1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate assembly must be replaced.



2. Visually inspect the facing surfaces
2 for cracking and
excessive scorching.
Visually inspect the facing surfaces for the presence of oil or grease.
If any of these conditions are discovered, the facing must be cleaned or replaced.



3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed with an oil stone.


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ISUZU KB P190 2007

CLUTCH 7C-41
HYDRAULIC DAMPER CYLINDER
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.






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ISUZU KB P190 2007