Page 4585 of 6020

MSG MODEL 7B-21
Important Operations
9. Counter End Ball Bearing
10. Counter 5th Gear
Use a gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)
15. Mainshaft Lock Nut and Washer
1) Engage the 3rd - 4th synchronizer with the 3rd gear.
2) Engage the 1st - 2nd synchronizer with the 1st gear.
3) Attach a holding fixture to the mainshaft and the countergear.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Use a lock nut wrench to remove the lock nut.
Lock Nut W rench: 5-8840-0353-0 (J-36629)
16. Rev. - 5th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
26. Bearing Snap Ring
1) Insert the snap ring pliers
1 into the counter gear bearing
snap ring hole
2.
The snap ring hole is in the intermediate plate
3.
2) Use the snap ring pliers to force open the counter gea
r
bearing snap ring.
Tap on the front of the intermediate plate.
The ball bearing snap ring will come free.
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Page 4586 of 6020
7B-22 MSG MODEL
27. Bearing Snap Ring
28. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap ring hole.
The snap ring hole is in the intermediate plate
2.
2) Use the snap ring pliers
1to force open the mainshaft
bearing snap ring
3.
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the transmission to remove it.
The ball bearing snap ring will come free.
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ISUZU KB P190 2007
Page 4587 of 6020
MSG MODEL 7B-23
TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR
Disassembly Steps
1. Top gear shaft snap ring
2. Top gear shaft
3. Ball bearing
4. Needle bearing
5. 4th block ring
6. Mainshaft snap ring
7. 3rd - 4th synchronizer assembly
8. 3rd block ring
9. 3rd gear
10. Needle bearing
11. Mainshaft ball bearing
12. 1st gear thrust washer
13. 1st gear
14. Needle bearing collar
15. Needle bearing
16. 1st block ring
17. 1st - 2nd synchronizer assembly
18. 2nd block ring
19. 2nd gear
20. Needle bearing
21. Mainshaft
22. Rear ball bearing
23. Bearing snap ring
24. Front ball bearing
25. Counter gear
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Page 4588 of 6020
7B-24 MSG MODEL
Ball bearing J-22912-01
Important Operations
1. Top Gear Shaft Snap Ring
2. Top Gear Shaft
3. Ball Bearing
1) Use a pair of snap ring pliers to remove the snap ring.
2) Use a bench press and a bearing remover to remove the ball bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)
7. 3rd - 4th Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
11. Mainshaft Ball Bearing
Use a bench press and a bearing remover to remove the ball
bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)
17. 1st - 2nd Synchronizer Assembly
1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
22. Rear Ball Bearing
24. Front Ball Bearing
Use a bench press and a bearing remover to remove the ball
bearing.
Bearing Removar : 5-8840-0015-0 (J-22912-01)
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ISUZU KB P190 2007
Page 4589 of 6020

MSG MODEL 7B-25
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness mm(in)
Standard Limit
1st-2nd 9.6-9.8 (0.378-0.386) 9.0 (0.354)
3rd-4th 6.95-7.2 (0.274-0.283) 6.5 (0.256)
Rev.-5th 6.8-6.9 (0.268-0.272) 6.3 (0.248)
DETENT SPRING FREE LENGTH
Use a venier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the detent
spring must be replaced.
Detent Spring Free Length mm(in)
Standard Limit
25.6 (1.01)23.6 (0.93)
DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension N(kg/lb)
Compressed
Height mm(in) Standard
Limit
22.1 (0.870)61.8-65.7
(6.3-6.7/13.9-14.8) 55.9
(5.7/12.6)
BLOCK RING AND DOG TEETH
CLEARANCE
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 block
ring must be replaced.
Block Ring and Dog Teeth Clearance mm(in)
Standard Limit
1st,2nd 2.0 (0.079) 1.3 (0.051)
3rd, 4th, 5th 1.5 (0.059) 0.8 (0.031)
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Page 4590 of 6020

7B-26 MSG MODEL
BLOCK RING AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
Block Ring and Insert Clearance mm(in)
StandardLimit
1st,2nd 3.46-3.74 (0.136-0.147)
3rd, 4th, 5th 3.51-3.79 (0.138-0.149)4.0 (0.157)
CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the
clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
Clutch Hub and Insert Clearance mm(in)
Standard Limit
0.01 - 0.19 (0.0004 - 0.0075) 0.3 (0.012)
MAINSHAFT RUN - OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.
Mainshaft Run - Out mm(in)
Limit
Less than 0.03 (0.0012)
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.
Gear Inside Diameter mm(in)
Standard Limit
1st
Rev. 45.00-45.01
(1.7717-1.7720) 45.10 (1.7756)
2nd
3rd 41.00-41.01
(1.6142-1.6146) 41.10 (1.6181)
5th34.03-34.04
(1.3398-1.3402) 34.10 (1.3425)
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Page 4591 of 6020

MSG MODEL 7B-27
REVERSE IDLER GEAR AND IDLER
GEAR SHAFT CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to measure the idler gear inside diameter.
3. Calculate the idler gear and idler gear shaft clearance.
Idler gear inside diameter - idler gear shaft diameter = idle
r
gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the idle
r
gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance mm(in)
Standard Limit
0.041 - 0.074 (0.0016 - 0.0029) 0.150 (0.0059)
CLUTCH HUB SPLINE PLAY
1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
It the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch Hub Spline Play mm(in
)
Standard Limit
0 - 0.019 (0 - 0.0075) 0.20 (0.0079)
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ISUZU KB P190 2007
Page 4592 of 6020
7B-28 MSG MODEL
BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play mm(in)
Limit
0.2 (0.0079)
FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.
Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer : 5-8840-0026-0 (J-26540)
2. Apply engine oil to the oil seal lip.
REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.
Oil Seal Installation
1. Use a oil seal installer to install the oil seal to the rear cover.
Oil Seal Installer : 5-8522-0050-0 (J-29769)
2. Apply engine oil to the oil seal lip.
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ISUZU KB P190 2007