Isuzu KB P190. Service manual — part 1182
Manual Transmission (MUX) 7B1-9
• Apply alignment marks on the flange at the
differential side.
9. Remove the front propeller shaft. (4x4 model)
• Apply alignment marks on the flange at both
front and rear side.
10. Disconnect the harness connectors and clips on
the transmission.
Legend
1. Neutral switch connector
2. Clutch damper valve connector
Legend
3. Clip
4. Reverse switch connector
5. 1st switch connector
RTW77BSH000201
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RTW77BSH006601
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7B1-10 Manual Transmission (MUX)
Legend
6. Car speed sensor conector
7. Clip
8. 2-4 switch connector (4x4 model)
9. Neutral switch connector (4x4 model)
10. Transfer actuator connector (4x4 model)
11. Remove the harness bracket fixing bolt on the
transmission left side.
12. Remove the slave cylinder fixing bolts.
13. Remove the fuel pipe bracket fixing bolt and
disconnect fuel pipe clip.
14. Remove the clutch housing cover and clutch
bearing dust cover.
15. Use the remover 5-8840-2291-0 to disconnect the
clutch release bearing from the clutch pressure
plate.
a. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
b. Insert the remover between the wedge collar
and the release bearing.
c. Turn the remover to separate the release
bearing.
Notice:
Be sure not to insert the remover between the wedge
collar and the clutch.
Legend
1. Release bearing
2. Pressure plate assembly
3. Bearing remover : 5-8840-2291-0
4. Wedge collar
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RTW77BSH000301
RTW77BSH000801
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Manual Transmission (MUX) 7B1-11
Legend
1. Correct procedure
2. Wrong procedure
3. Front
4. Wedge collar
5. Clutch release bearing
6. Bearing remover : 5-8840-2291-0
• When clutch release bearing cannot be
removed (For instance, transformation of
wedge collar, and other reasons), remove
the shift fork in order of the following with a
tool of L-type (2) as shown in figure.
1) Remove the snap pin (1).
2) Remove the shift fork pin (4).
3) Remove the shift fork (3).
Notice:
Do not remove by this method usually.
The clutch release bearing or wedge collar might be
damaged with the input shaft of transmission at
removed the transmission because the clutch release
bearing is adhered to clutch.
16. Support transmission assembly (4x2 model) or
transmission & transfer assembly (4x4 model) with
a transmission jack.
17. Remove the transmission rear mount nuts fixing on
crossmember from the transmission crossmember.
18. Remove the transmission crossmember by
removing four fixing bolts and nuts.
19. Remove the transmission rear mount.
20. Remove the starter assembly.
21. Disconnect harness clips on the transmission left
side.
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RTW77BSH006901
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RTW77BSH000401
7B1-12 Manual Transmission (MUX)
22. Remove the transmission retaining nuts and bolts.
Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.
23. Remove the transmission-transfer fixing bolts and
nut, and disassemble the transfer from the
transmission. (4x4 model)
Installation
1. Apply grease (BESCO L-2 or equivalent) on the
splined portion of the output shaft.
2. Connect the transfer to the transmission. (4x4
model)
3. Install the transmission-transfer fixing bolts and
nut, and tighten them to the specified torque. (4x4
model)
Torque: 41 N
⋅m (4.2 kgf⋅m/30 lb⋅ft)
4. Apply a thin coat of molybdenum disulfide grease
on the splined portion of the input shaft spline.
5. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
6. Align the input shaft spline with the clutch driven
plate spline.
7. Install the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
to the engine.
• Tighten the transmission bolts to the specified
torque.
Torque: 76 N
⋅m (7.7 kgf⋅m/56 lb⋅ft)
8. Apply a force 69 N
⋅m (7 kgf⋅m/51 lb⋅ft) to the tip of
the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.
Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N
⋅m (2.6 kgf⋅m/19 lb⋅ft). If
the shift fork will not move, then they are securely
engaged.
9. Connect harness clips on the transmission left
side.
10. Install the starter assembly.
• Tighten the starter bolts to the specified torque.
Torque: 94 N
⋅m (9.6 kgf⋅m/69 lb⋅ft)
11. Install the transmission rear mount to the
transmission.
• Tighten the transmission rear mount bolts to the
specified torque.
Torque: 50 N
⋅m (5.1 kgf⋅m/37 lb⋅ft)
12. Install the transmission crossmember by removing
four bolts and nuts.
• Tighten the transmission crossmember bolts to
the specified torque.
Torque: 67 N
⋅m (6.8 kgf⋅m/49 lb⋅ft)
13. Install the transmission rear mount nuts fixing on
crossmember from transmission crossmember.
• Tighten the transmission rear mount nuts to the
specified torque.
Torque: 52 N
⋅m (5.3 kgf⋅m/38 lb⋅ft)
Remove the transmission jack from transmission
side.
14. Install the fuel pipe bracket bolt and connect fuel
pipe clip.
• Tighten the fuel pipe bracket bolt to the
specified torque.
Torque: 76 N
⋅m (7.7 kgf⋅m/56 lb⋅ft)
15. Install the slave cylinder fixing bolts.
• Tighten the slave cylinder bolts to the specified
torque.
Torque: 43 N
⋅m (4.4 kgf⋅m/32 lb⋅ft)
RTW77BSH007201
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