Isuzu KB P190. Manual — part 1174

7B1-90 MANUAL TRANSMISSION

Disassembly

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

shaft snap ring.

2. Remove the top gear shaft with ball bearing.

3. Use a bench press and the bearing remover 5-8840-

0015-0 to remove the ball bearing.

226RW216

4. Remove the needle bearing and top block ring,

mainshaft snap ring.

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

mainshaft snap ring.

226RS008

6. Use a bench press and the bearing remover 5-8840-

0015-0 to remove the 3rd-4th synchronizer
assembly as a set.

Disassemble the synchronizer assembly.

226RW217

Legend

(1)

Springs

(2)

Sleeve

(3)

Clutch Hub

(4)

Inserts

7. Remove the 3rd block ring, 3rd gear, and needle

bearing.

8. Use a bench press and the bearing remover 5-8840-

0015-0 to remove the 1st gear together with the
mainshaft ball bearing, 1st gear thrust bearing, and
the needle bearing collar.

226RW218

MANUAL TRANSMISSION 7B1-91

9.Disassemble the 1st inside ring, 1st outside ring, and

1st block ring.

10.Remove the needle bearing.
11.Use a pair of snap ring pliers to remove the clutch

hub snap ring.

226RS031

12.Use a bench press and the bearing remover 5-8840-

0015-0 to remove the 2nd gear together with 1st-2nd
synchronizer assembly, 2nd block ring, 2nd outside
ring, and inside ring.
Disassemble the synchronizer assembly.

226RW220

Legend

(1) Springs

(2) Sleeve

(3) Clutch

Hub

(4) Inserts

13. Remove the needle bearing from the mainshaft.

14. Remove the bearing snap ring.

15. Remove the front roller bearing by performing the

following steps.
• Remove the ring, outer race and bearing

assembly by using a bench press and remover
5-8840-0015-0.

• Remove the inner race by using a bench press

and remover 5-8840-0015-0.

226RW219

16. Remove the center roller bearing from the counter

gear shaft.

7B1-92 MANUAL TRANSMISSION

Inspection and Repair

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.

Block Ring and Dog Teeth Clearance

• Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.

226RS035

If the measured value exceeds the specified limit,
the block ring must be replaced.

Block Ring and Dog Teeth Clearance

Standard Limit

1.5 mm (0.059 in)

0.8 mm (0.031 in)

MANUAL TRANSMISSION 7B1-93

1st-2nd Synchronizer (3-CONE)

• Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.

226RS036

If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.

Block Ring and Dog Teeth Clearance

Standard Limit

1.5 mm (0.059 in)

0.8 mm (0.031 in)

Block Ring and Insert Clearance

• Use a vernier caliper or thickness gauge to measure

the clearance between the block ring and the insert.

226RS037

If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.

Block and Insert Clearance

Standard Limit

3rd-4th

3.46 - 3.76 mm

(0.136 - 0.148 in)

4.0 mm

(0.157 in)

1st-2nd

3.86 – 4.16 mm

(0.152 - 0.164 in)

4.9 mm

(0.193 in)

Rev.5th

3.59 - 3.91 mm

(0.141 - 0.154 in)

4.1 mm

(0.161 in)

Clutch Hub and Insert Clearance

• Use a thickness gauge to measure the clearance

between the clutch hub and the insert.

226RS038

If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.

Clutch Hub and Insert Clearance

Standard Limit

1st-2nd

3rd-4th

0.01 – 0.21 mm

(0.0004 - 0.0083 in)

0.3 mm

(0.012 in)

Rev-5th

0.09 – 0.31 mm

(0.0035 - 0.0122 in)

0.4 mm

(0.016 in)