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.