Isuzu KB P190. Manual — part 1169

7B1-70 MANUAL TRANSMISSION

15. Tighten the exhaust pipe fixing nuts to the specified

torque. (Diesel engine only)

Torque: 67 N

⋅⋅⋅⋅m (6.8 kgf⋅⋅⋅⋅m/49 lb⋅⋅⋅⋅ft)

RTW67BSH000101

16. Install the front propeller shaft.

Refer to the section “Front Propeller Shaft”.

17. Install the rear propeller shaft.

Torque: 59 N

⋅⋅⋅⋅m (6.0 kgf⋅⋅⋅⋅m/43 lb⋅⋅⋅⋅ft)

18. Install the center bearing on crossmember.

Torque: 69 N

⋅⋅⋅⋅m (7.0 kgf⋅⋅⋅⋅m/51 lb⋅⋅⋅⋅ft)

19. Install the gear control lever.

Torque: 19 N

⋅⋅⋅⋅m (1.9 kgf⋅⋅⋅⋅m/14 lb⋅⋅⋅⋅ft)

20. Install the grommet assembly.

Torque: Screw

1.4 N

⋅⋅⋅⋅m (0.14 kgf⋅⋅⋅⋅m/12 lb⋅⋅⋅⋅in)

Nut 7

N

⋅⋅⋅⋅m (0.7 kgf⋅⋅⋅⋅m/61 lb⋅⋅⋅⋅in)

RTW47BMH000101

Legend

(1)

Grommet Assembly

(2)

Floor Panel

(3)

Front

21. Install the front floor console and rear floor console.

22. Install the gear control lever knob.

To the female thread portion, apply 3 - 4 drops of
adhesive (TB1344 or LOCTITE 222 or equiv.) and
tighten the transmission knob.

Torque: 9 N

⋅⋅⋅⋅m (0.9 kgf⋅⋅⋅⋅m/78 lb⋅⋅⋅⋅in)

After tightening to specified torque, rewrench the
knob until the direction of the shift pattern is in the
due position.

23. Connect the battery ground cable.

MANUAL TRANSMISSION 7B1-71

Transmission Case

Major Component

RTW77BLF003701

Legend

(1) Gear Control Box Assembly and Gasket

(7) Counter Front Bearing Snap Ring

(2) Rear Case Assembly

(8) Front Cover (with Oil Seal)

(3) Intermediate Plate with Gear Assembly

(9) Top Gear Bearing Snap Ring

(4) Transmission Case

(10) Release Bearing: C24SE

(5) Release Bearing (with Spring): Diesel engine

(11) Shift Fork: C24SE

(6) Shift Fork and Cover: Diesel engine

7B1-72 MANUAL TRANSMISSION

Disassembly

1. Clean the exterior of the unit with solvent.

2. Remove the drain plug from the transmission case

and drain the lubricant.

3. Remove the clutch release bearing with spring from

the transmission case.

4. Remove the shift fork, and boot.

5.

Remove the front cover and gasket from the
transmission case.

6. Remove the snap ring fixing counter front bearing.

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

ring fixing top gear bearing.

226RS001

8. Remove the gear control box assembly.

9.

Remove the rear case assembly from the
transmission case and intermediate plate.

10. Remove the intermediate plate with gear assembly

from the transmission case.

Rear Oil Seal Replacement

220R300025

Legend

(1)

Installer 5-8840-2797-0

(2)

Grip 5-8840-0007-0

1. Remove the oil seal from the rear case and discard

the used oil seal.

2. Apply engine oil to the new oil seal outer surfaces.

3. Apply recommended grease (BESCO L2) or

equivalent to the oil seal lip.

4. Use the oil seal installer 5-8840-2797-0 and grip 5-

8840-0007-0 to install the oil seal to the rear case.

Reassembly

1.

Apply recommended liquid gasket (Three Bond
TB1215) or its equivalent to the transmission case,
intermediate plate and rear case fitting surfaces.

2. Install the intermediate plate with gear assembly to

the transmission case.

Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.

Avoid subjecting the mainshaft to sudden shock or
stress.

3. Install the rear case with oil seal on the intermediate

plate, with gear, by performing the following steps.
• Cover the shaft splines with adhesive tape.

This will prevent damage to the oil seal lip.

• Tighten the transmission rear case bolts and

nuts to the specified torque.

Torque: 37 N

⋅⋅⋅⋅m (3.8 kgf⋅⋅⋅⋅m/27 lb⋅⋅⋅⋅ft)

MANUAL TRANSMISSION 7B1-73

mm (in)

RTW77BSH008601

Notes When Tightening the Bolt:

• After cleaning the bolt hole, air dry it thoroughly.

• After cleaning the screw face of a removed or new

bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.

4. Install a new gasket and gear control box assembly.

Install the harness clips and brackets and then
tighten the four new gear control box bolts to the
specified torque.

Torque: 20 N

⋅⋅⋅⋅m (2.0 kgf⋅⋅⋅⋅m/14 lb⋅⋅⋅⋅ft)

261R300004

5. Install the top gear bearing snap ring and counter

front bearing snap ring.
• Use a pair of snap ring pliers to install the snap

rings to the mainshaft and countershaft.

• The snap rings must be fully inserted into the

bearing snap ring groove.

6. Front cover with oil seal.

Front Cover Oil Seal Replacement

• Remove the oil seal from the front cover.
• Apply engine oil to the outer circumference of

new oil seal.

• Apply recommended grease to the oil seal lip.
• Use the oil seal installer 5-8840-0026-0 to install

the oil seal to the front cover.

220R300002

7.

Install a new gasket and front cover to the
transmission case.

NOTE: Take care not to damage the oil seal.

Notes When Tightening the Bolt:

• After cleaning the bolt hole, air dry it thoroughly.

• After cleaning the screw face of a removed or new

bolt, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening.

Tighten the six front cover bolts to the specified
torque.

Torque: 25 N

⋅⋅⋅⋅m (2.6 kgf⋅⋅⋅⋅m/19 lb⋅⋅⋅⋅ft)