Isuzu KB P190. Manual — part 1171

7B1-78 MANUAL TRANSMISSION

Reassembly

1. Install the rev-5th shift arm and reverse inhibitor and

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 the 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 the 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

MANUAL TRANSMISSION 7B1-79

Reverse Gear and 5th Gear

Disassembled View

226R300024

Legend

(1) Collar Snap Ring

(15) Counter 5th Gear

(2) Oil Seal Collar

(16) Counter Reverse Gear

(3) Ball Bearing

(17) 5th Gear

(4) Retainer

(18) 5th Block Ring

(5) Thrust Plate

(19) Needle Bearing

(6) Thrust Washer and Lock Ball

(20) Mainshaft Nut

(7) Reverse Idler Gear Snap Ring

(21) Rev-5th Synchronizer Assembly

(8) Reverse Idler Gear Assembly

(22) Reverse Block Ring

(9) Idle Shaft Pin

(23) Reverse Gear

(10) Thrust Washer

(24) Needle Baring

(11) Reverse Idler Gear

(25) Bearing Plate and Screw

(12) Reverse Idler Shaft

(26) Bearing Snap Ring

(13) Bearing Snap Ring

(27) Intermediate Plate

(14) Ball

Bearing

7B1-80 MANUAL TRANSMISSION

Disassembly

1. Use a pair of snap ring pliers to remove the collar

snap ring.

2. Set the mainshaft retainer remover 5-8840-2158-0

and puller 5-8840-2027-0 to the retainer and the
mainshaft end.

262RW079

3. Remove the retainer together with the bearing and

the oil seal collar.

The universal puller may be used in place of the
retaining ring remover.

4. Remove the thrust plate, thrust washer and lock

ball.

5. Use a pair of snap ring pliers to remove reverse idler

gear snap ring.

226RS004

6. Remove the reverse idler gear assembly from the

intermediate plate.

226RS005

7. Remove the idle shaft pin, thrust washer, reverse

idler gear, and reverse idler shaft.

8. Use a pair of snap ring pliers to remove the snap

ring.

9. Attach a universal puller to the counter gear shaft.

Use a universal puller to remove the ball bearing
and the counter 5th gear.

226RS006

10. Remove the counter reverse gear.

MANUAL TRANSMISSION 7B1-81

11. Remove the 5th gear, 5th block ring, and needle

bearing (2 piece type).

226RS007

12. Remove the mainshaft nut according to following

steps.

Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.

226RW212

• Engage the 3rd-4th synchronizer with the 3rd

gear.

• Engage the 1st-2nd synchronizer with the 1st

gear.

226RW210

• Use the mainshaft nut wrench 5-8840-2156-0 to

remove the mainshaft nut.

226RW211