Isuzu KB P190. Manual - part 1158

7B1-26     MANUAL TRANSMISSION 

Disassembly 

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

snap ring. 

 2. Set the bearing remover 5-8840-2155-0 and the 

puller 5-8840-2027-0 to the bearing

and the 

mainshaft end, to remove the ball bearing. 

262L100001

 3. Remove the bearing snap ring, clip, speedometer

drive gear, retainer snap ring and the retainer. 

 4. Remove the thrust plate, thrust washer and lock

ball. 

  5. Use a pair of snap ring pliers to remove the 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     7B1-27 

 

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 the 
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

 

 

 

 

7B1-28     MANUAL TRANSMISSION 

 13. Use screw drivers between the reverse gear and the 

bearing plate to remove the Rev-5th synchronizer
assembly, together with the reverse block ring and
reverse gear. 

  

226RS010

14. Remove the needle bearing. 

 

15. Use the torx bit wrench (T- 45) 5-8840-0047-0 to 

remove the bearing plate and screw from the
intermediate plate. 

 

220RW137

16. Use the snap ring pliers (1) to remove the mainshaft

bearing snap ring (2). 

 

 

  

226RS011

 17. Hold the snap ring open with the pliers. 

Push the intermediate plate toward the rear of the 
transmission to remove it. 

The bearing snap ring will come free. 

 

Inspection and Repair 

Refer to Top Gear Shaft, Main Gear Shaft, and Counter 
Gear in this section for inspection and repair. 

 

Reassembly 

  1. Mesh the counter gear with the mainshaft assembly.

Set the holding fixture 5-8840-2160-0 to the 
mainshaft and the counter gear, and then install it on 
the base 5-8840-0003-0. 

Install the intermediate plate on the gear assembly.

226RW212

 

 

MANUAL TRANSMISSION     7B1-29 

  2. Install the bearing snap ring. 

 3. Apply the recommended thread locking agents

(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads. 

Install the bearing plate and screw. 

Tighten the screws to the specified torque by using
torx bit wrench (T- 45) 5-8840-0047-0. 

Torque: 15 N

⋅⋅⋅⋅m (1.5 kgf⋅⋅⋅⋅m/11 lb⋅⋅⋅⋅ft) 

 

220RW137

  4. Install the needle bearing, reverse gear, and reverse

block ring. 

   

5. 

Assemble rev-5th synchronizer assembly by 
performing the following steps. 

1.  Turn the clutch hub face (1) toward the sleeve 

groove (2) (rear side) on the outer 
circumference. 

2.  Check that the inserts (3) fit snugly into the 

clutch hub (5) ring insert grooves. 

3.  Check that the inserts springs (4) are fitted to 

the inserts as shown in the illustration. 

4.  Check that the clutch hub (5) and the sleeve (6) 

slide smoothly. 

5. Install the synchronizer assembly to the 

mainshaft. 

The clutch hub face with the heavy boss must be 
facing the reverse gear side. 

  

226RS013

  

226RS049