Isuzu KB P190. Manual — part 1162
7B1-42 MANUAL TRANSMISSION
• Use bearing installer 5-8840-2194-0 to install the
ring.
RTW57BSH000101
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner
Race
3. Install the bearing snap ring to the counter gear
shaft.
4. Apply engine oil to the needle bearing and the 2nd
gear thrust surfaces.
Install the needle bearing and the 2nd gear to the
mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.
226RS046
5. Assemble the 2nd inside ring, 2nd outside ring, and
2nd block ring on the 2nd gear.
• Apply engine oil to the synchronizer ring friction
surfaces.
226RS047
Legend
(1)
Block Ring
(2)
Outside Ring
(3)
Inside Ring
(4)
2nd Gear
(5)
Needle Bearing
MANUAL TRANSMISSION 7B1-43
6.
Assemble 1st-2nd synchronizer assembly by
performing the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub (5) insert grooves.
2. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
266RS049
7. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be
facing the 2nd gear side.
226RS048
8. Install the clutch hub snap ring by performing the
following steps:
• Select the snap ring which will provide the
minimum clearance between the 1st-2nd clutch
hub and the snap ring.
226RS050
• There are three snap ring sizes available.
• The snap rings are color-coded to indicate their
thickness as shown in the figure.
226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color
Coding
1.80 mm (0.071 in)
White
1.85 mm (0.073 in)
Yellow
1.90 mm (0.075 in)
Blue
• Use a pair of snap ring pliers to install the snap
ring to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
7B1-44 MANUAL TRANSMISSION
226RS031
9. Install the needle bearing, 1st block ring, 1st outside
ring , 1st inside ring, and 1st gear.
• Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
• The 1st gear dog teeth must be facing the
transmission front side.
226RS053
Legend
(1) 1st
Gear
(2) Needle
Bearing
(3) Inside
Ring
(4) Outside
Ring
(5) Block
Ring
10. Install the 1st gear thrust bearing and the race to the
main shaft.
The thrust bearing side must be facing the
transmission front side.
226RS054
11. Apply engine oil to the mainshaft ball bearing and
the mainshaft.
Install the ball bearing and needle bearing collar to
the mainshaft.
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.
226RS055
MANUAL TRANSMISSION 7B1-45
12. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing and the 3rd gear to the
mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.
226RS056
13. Install the 3rd block ring.
14. Check and install the 3rd-4th synchronizer assembly
using the following steps:
1. Check that the inserts (3) fit snugly into the
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts, as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the 3rd gear side.
226RS049
226RW221
15. Select and install mainshaft snap ring using the
following instructions:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.
226RS058
There are three snap ring sizes available.
The snap rings are color-coded to indicate their
thickness as shown in the figure.
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