2007 ISUZU KB P190 Workshop Repair Manual

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Page 4713 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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
Readju

Page 4714 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7B1-108 MANUAL TRANSMISSION
Checkpoint Trouble Cause Countermeasure

Synchronizer assembly
Shift arm and synchronizer
sleeve
Replace the worn parts
Replace the worn parts
W orn synchronizer

Page 4715 of 6020

ISUZU KB P190 2007 Workshop Repair Manual MANUAL TRANSMISSION 7B1-109
3. WALKING OR JUMPING OUT OF GEAR

Checkpoint Trouble Cause Countermeasure

Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or

Page 4716 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7B1-110 MANUAL TRANSMISSION
Checkpoint Trouble Cause Countermeasure

Synchronizer assembly
Bearings (Mainshaft,
countershaft, and individual
gears)
Replace the spring
Replace the bearing(s)

Page 4717 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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
re

Page 4718 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7B1-112 MANUAL TRANSMISSION
Special Tools (4×
××
×
4)

ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2158-0
(J-37222)
Mainshaft retainer remover 5-8

Page 4719 of 6020

ISUZU KB P190 2007 Workshop Repair Manual MANUAL TRANSMISSION 7B1-113
ILLUSTRATION TOOL NO.
TOOL NAME
5-8840-2194-0
Bearing installer

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ISUZU KB P190 2007

Page 4720 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Manual Transmission (MUX) 7B1-1
TRANSMISSION/TRANSAXLE
Manual Transmission(MUX)
TABLE OF CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . 7B1-2 General Description . . . .

Manual Transmission (MUX) 7B1-1
TRANSMISSION/TRANSAXLE
Manual Transmission(MUX)
TABLE OF CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . 7B1-2 General Description . . . . . . . . . . . . . . . . . . . . . 7B1-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7B1-4
Main Specifications . . . . . . . . . . . . . . . . . . . . . 7B1-5
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-6
Transmission Assembly . . . . . . . . . . . . . . . . . . . 7B1-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-12
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-16 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-18
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-24
Front Case Assembly . . . . . . . . . . . . . . . . . . . . 7B1-34 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-35
Rear Case Assembly . . . . . . . . . . . . . . . . . . . . 7B1-36 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-37
End Cover Assembly. . . . . . . . . . . . . . . . . . . . . 7B1-39 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-39
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . 7B1-40 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-40
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-41
Counter Shaft Assembly . . . . . . . . . . . . . . . . . . 7B1-43 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-43
Inspection and Repair . . . . . . . . . . . . . . . . . . 7B1-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-47
Output Shaft Assembly . . . . . . . . . . . . . . . . . . . 7B1-50 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-50
Shift & Select Rod Assembly . . . . . . . . . . . . . . 7B1-51 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-51
Intermediate Plate Assembly . . . . . . . . . . . . . . 7B1-53 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-53
Control Rod Assembly . . . . . . . . . . . . . . . . . . . 7B1-55 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-55
5th-Reverse Shift Block Assembly . . . . . . . . . . 7B1-56 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-56
3rd-4th Shift Arm Assembly. . . . . . . . . . . . . . . . 7B1-57 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-57
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-58 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 7B1-58

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