Isuzu KB P190. Service manual — part 1165
7B1-54 MANUAL TRANSMISSION
Checkpoint
Trouble
Cause
Countermeasure
Synchronizer assembly
Shift arm and synchronizer
sleeve
Replace the worn parts
Replace the worn parts
Worn synchronizer parts
Worn shift arm and/or
synchronizer sleeve groove
Mainshaft and countershaft
thrust play
Replace the worn parts
Worn thrust washer, collar,
and/or gear thrust faces
OK
NG
NG
NG
OK
OK
Continued from the previous
MANUAL TRANSMISSION 7B1-55
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
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent spring
Repair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OK
NG
NG
NG
NG
OK
OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust play
Replace the worn parts
Worn thrust washer, collar,
and/or gear thrust faces
Replace the worn parts
Worn shift arm and/or
synchronizer sleeve groove
NG
NG
OK
Shift arm and synchronizer
sleeve
7B1-56 MANUAL TRANSMISSION
Checkpoint
Trouble
Cause
Countermeasure
Synchronizer assembly
Bearings (Mainshaft,
countershaft, and individual
gears)
Replace the spring
Replace the bearing(s)
Weak or broken spring
Worn or broken bearings(s)
Mainshaft splines
Synchronizer clutch hub
splines
Replace the main shaft and
the synchronizer clutch hub
Worn splines
OK
NG
NG
NG
OK
OK
Continued from the previous page
MANUAL TRANSMISSION 7B1-57
4. OIL LEAKAGE
Checkpoint
Trouble
Cause
Countermeasure
Gear oil
Replace the gear oil
Improper gear oil
Drain plug and/or filler plug
Tighten 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
OK
Oil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
Worn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil seal
Replace the oil seal
Replace the gasket(s)
Worn or scratched oil seal
Defective or improperly
installed gasket(s)
OK
NG
NG
NG
NG
OK
OK
Gaskets
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