2007 ISUZU KB P190 service

ON-VEHICLE SERVICE (JR405E) 7A3-23
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME


5-8840-2763-0

Inhibitor Switch Set Plate


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-1
SECTION 7A4
UNIT REPAIR (JR405E)
TABLE OF CONTENTS
PAGE
Automatic Transmission Disassembly ...................................................................... 7A4- 2
Control Valve Assembly ............................................................................................. 7A4-11
Control Valve Upper Body ......................................................................................... 7A4-18
Control Valve Lower Body ......................................................................................... 7A4-23
Oil Pump Assembly .................................................................................................... 7A4-28
Clutch Pack (Reverse and High Clutch Assembly) ................................................. 7A4-32
Carrier and Low Clutch Assembly ............................................................................ 7A4-41
Transmission Case .................................................................................................... 7A4-54
Bearing and Bearing Race Installation Position ...................................................... 7A4-66
Automatic Transmission Reassembly ...................................................................... 7A4-69
Service Standard ........................................................................................................ 7A4-8 3
Special Service Tool ................................................................................................... 7A4-85




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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-83
SERVICE STANDARD
Name BESCO ATF III ATF
Quantity L (US gal/Imp gal) 9.2 – 9.6 (2.43-2.54/2.02-2.11)
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plates / driven plates 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coils 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring Linear diameter mm (in) 1.2 (0.047)
Number of drive plates / driven plates 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coils 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring Linear diameter mm (in) 1.1 (0.043)
Number of drive plates / driven plates 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.024 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in) 5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plates / driven plates
6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)

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ISUZU KB P190 2007

7A4-84 UNIT REPAIR (JR405E)
SERVICE STANDARD (Cont’d)
Number of coils 4.8
Outside diameter mm (in) 11.2 (0.441)
Free length mm (in) 22.3 (0.878)
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drives / driven plates 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and retaining plate clearance mm (in) 1.0 – 1.4 (0.039 – 0.055)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
6.0 (0.236)
6.2 (0.244)
Available 2-4 brake retaining plate thickness mm (in)
6.4 (0.252)
Number of coils 10.2
Outside diameter mm (in) 6.9 (0.272)
Free length mm (in) 22.5 (0.886)
2-4 brake
Return spring Linear diameter mm (in) 1.1 (0.043)
Output shaft Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Total end play mm (in) 0.25 – 0.55 (0.0098 – 0.0217)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
2.2 (0.087)
Total end play
Available oil pump bearing race thickness mm (in)
2.4 (0.094)
Torque converter end play mm (in) 67.0 (2.638)


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ISUZU KB P190 2007

UNIT REPAIR (JR405E) 7A4-85
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME


5-8841-0841-0

Holding Fixture


5-8840-0003-0

Holding Fixture Base


5-8840-2764-0

2-4 Brake Spring Compressor


5-8840-2767-0

High Clutch Spring Compressor


5-8840-2759-0

Low Clutch Spring Compressor


5-8840-2761-0

Oil Pump Oil Seal Installer


5-8840-2769-0

Rear Extension Oil Seal Installer


5-8840-2770-0

Rear Adapter Oil Seal Installer


5-8840-2758-0

Manual Shaft Oil Seal Installer

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ISUZU KB P190 2007

MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION (MSG)
TABLE OF CONTENTS
PAGE
Main Data and Specifications ..................................................................................... 7B - 2
General Description .................................................................................................... 7B - 3
Torque Specification ................................................................................................... 7B - 4
Repair Kit .................................................................................................................... 7B - 6
Removal and Installation ........................................................................................... 7B - 7
Disassembly ................................................................................................................ 7B - 15
Inspection and Repair ................................................................................................ 7B - 25
Reassembly ................................................................................................................. 7B - 29
Special Service Tool ................................................................................................... 7B - 42


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ISUZU KB P190 2007

7B-42 MSG MODEL
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

9-8529-2201-0
Spring pin remover
5-8840-0013-0
(J-22888) Gear remover
5-8840-2001-0
(J-29768) Holding fixture

5-8840-0353-0
(J-36629) Lock nut wrench
5-8840-0015-0
(J-22912-01) Bearing remover/installer
5-8840-0026-0
(J-26540) Oil seal installer

5-8522-0050-0
(J-29769) Oil seal installer

5-8840-0178-0
(J-33851) Collar installer


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-1
SECTION 7B1
MANUAL TRANSMISSION
(MUA)
TABLE OF CONTENTS
PAGE
MUA5G/5H/5S (4 ×
××
×
2)
Service Precaution ......................................................................................................... 7B 1 – 3
General Description ........................................................................................................ 7B 1 – 4
Rear Oil Seal ................................................................................................................. .. 7B1 – 5
Transmission (4 ×
××
×
2) ......................................................................................................... 7B1 – 7
Disassembled View..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –11
Transmission Case .......................................................................................................... 7B1 –16
Major Component........................................................................................................ 7B1 –16
Disassembly ................................................................................................................ 7B1 –17
Reassembly ................................................................................................................. 7B1 –17
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –20
Disassembled View..................................................................................................... 7B1 –20
Disassembly ................................................................................................................ 7B1 –21
Inspection and Repair................................................................................................. 7B1 –22
Reassembly ................................................................................................................. 7B1 –23
Reverse Gear and 5th Gear ............................................................................................ 7B1 –24 Disassembled View..................................................................................................... 7B1 –24
Disassembly ................................................................................................................ 7B1 –26
Inspection and Repair................................................................................................. 7B1 –28
Reassembly ................................................................................................................. 7B1 –28
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –34 Disassembled View..................................................................................................... 7B1 –34
Disassembly ................................................................................................................ 7B1 –36
Inspection and Repair................................................................................................. 7B1 –38
Reassembly ................................................................................................................. 7B1 –41
Main Data and Specifications ......................................................................................... 7B1 –47

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ISUZU KB P190 2007