Isuzu KB P190. Manual — part 1157
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)
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 lower
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 lower
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)
Warped
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 Washer
(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 Washer and Lock Ball
(19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring
(20) 5th Gear
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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