Page 4625 of 6020
MANUAL TRANSMISSION 7B1-19
11. Apply molybdenum disulfide type grease to the
areas shown in the figure and install the shift fork.
F07L100026
12. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease, as shown in the figure.
A07RW 075
13. Install the release bearing on the front cover, joining it to the shift frok.
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ISUZU KB P190 2007
Page 4626 of 6020
7B1-20 MANUAL TRANSMISSION
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View
RTW 57BLF000201
Legend
(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly
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ISUZU KB P190 2007
Page 4627 of 6020
MANUAL TRANSMISSION 7B1-21
Disassembly
1. Remove the detent spring plate and gasket, the
detent spring and detent ball.
Use a magnetic hand to remove the detent balls
from the intermediate plate.
220RS011
2. Remove the spring.
3. Remove the rev-5th shift rod, and rev-5th shift arm and the reverse inhibitor.
Remove the 1st-2nd shift rod, 3rd-4th shift rod, 3rd-
4th shift arm, and 1st-2nd shift arm.
• Hold a round bar against the shift rod end.
230RS003
• Use a spring pin remover to remove the shift
arm spring pins from the shift arms, and the shift
rods.
230RS0004
•
Be careful not to lose the interlock pins, when
pulling out the shift rod rearward.
The interlock pins are located between the
shifter rods in the intermediate plate.
230RS0005
• Remove the rev-5th, 1st-2nd and 3rd-4th shift
rods carefully.
4. Remove the interlock pin from the intermediate plate and gear assembly.
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ISUZU KB P190 2007
Page 4628 of 6020

7B1-22 MANUAL TRANSMISSION
Inspection and Repair
Make the necessary adjustments 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
Standard Limit
1st-2nd 9.60 - 9.85 mm
(0.378 - 0.388 in)
3rd-4th
Rev.5th 9.60 - 9.80 mm
(0.378 - 0.386 in) 9.0 mm
(0.354 in)
230RS006
Detent Spring Free Length
• Use a vernier 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
Standard Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)
SOUTH AFRICA 5th-Rev Only
Detent Spring Free Length
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 in)
220RS012
Detent Spring Tension
• Use a spring tester to measure the detent spring
tension.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent Spring Tension
Compressed height Standard
20 mm (0.787 in) 87.2 - 97.1 N
(19.6 - 21.8 lb)
220RS013
SOUTH AFRICA 5th-RV Only
Detent Spring Free Length
Compressed Standard
Outer 20 mm (0.787 in) 93.5 – 103.3 N
(21.0 – 23.3 lb)
Inner 20 mm (0.787 in) 26.4 – 36.3 N
(5.9 – 8.2 lb)
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ISUZU KB P190 2007
Page 4629 of 6020

MANUAL TRANSMISSION 7B1-23
Reassembly
1. Install the rev-5th shift arm and reverse inhibitor and
the rev-5th shift rod.
• Apply oil to the reverse inhibitor inner surface.
• Install the shift rod in the intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.
• Install the interlock pin in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
2. Install the 1st-2nd shift arm and 3rd-4th shift arm to the intermediate plate and gear assembly.
3. Install the 3rd-4th shift rod and 1st-2nd shift rod. • Install the interlock pin in the intermediate plate
and gear assembly.
• Install the 3rd-4th shift rod in the intermediate
plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Install the interlock pin and then 1st-2nd shift rod
in the intermediate plate.
Do not allow the interlock pin to fall from the
intermediate plate.
• Hold a round bar against the shift rod end lowe
r
face to protect it against damage.
• Install a new spring pin.
Never reinstall the used spring pin.
230RS007
4. Install the spring.
5. Put the detent balls in the intermediate plate holes.• Apply oil to the detent balls.
6. Install the detent springs and detent spring plate and gasket.
NOTE: For South Africa model, it has double detent
spring for Rev-5th shift rod.
• Install a new gasket and the detent spring plate.
• Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)
220RS030
Legend
(1) W arped
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ISUZU KB P190 2007
Page 4630 of 6020
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
Page 4631 of 6020
MANUAL TRANSMISSION 7B1-25
(21) 5th Block Ring (26) Reverse Gear
(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate
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ISUZU KB P190 2007
Page 4632 of 6020
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