Isuzu KB P190. Manual - part 1165

7B1-54     MANUAL TRANSMISSION 

Checkpoint  

Trouble 

Cause 

 

Countermeasure 

 

Synchronizer assembly

Shift arm and synchronizer

sleeve

Replace the worn parts

Replace the worn parts

Worn synchronizer parts

Worn shift arm and/or

synchronizer sleeve groove

Mainshaft and countershaft

thrust play

Replace the worn parts

Worn thrust washer, collar,

and/or gear thrust faces

OK

NG

NG

NG

OK

OK

Continued from the previous

 

MANUAL TRANSMISSION     7B1-55 

3.  WALKING OR JUMPING OUT OF GEAR 

 

Checkpoint  

Trouble 

Cause 

 

Countermeasure 

 

Shift rod and quadrant box

sliding faces

Detent ball

Replace the shift rod and/or

the quadrant box

Replace the detent ball

Worn shift rod and/or sliding

faces

Worn detent ball

Detent spring

Repair or replace the detent

spring

Replace the worn parts

Detent spring weak or broken

Insufficient stroke caused by

sliding position wear and

excessive play

OK

OK

NG

NG

NG

NG

OK

OK

Change lever play

Continued on the next page

Mainshaft and countershaft

thrust play

Replace the worn parts

Worn thrust washer, collar,

and/or gear thrust faces

Replace the worn parts

Worn shift arm and/or

synchronizer sleeve groove

NG

NG

OK

Shift arm and synchronizer

sleeve

 

7B1-56     MANUAL TRANSMISSION 

Checkpoint  

Trouble 

Cause 

 

Countermeasure 

 

Synchronizer assembly

Bearings (Mainshaft,

countershaft, and individual

gears)

Replace the spring

Replace the bearing(s)

Weak or broken spring

Worn or broken bearings(s)

Mainshaft splines

Synchronizer clutch hub

splines

Replace the main shaft and

the synchronizer clutch hub

Worn splines

OK

NG

NG

NG

OK

OK

Continued from the previous page

 

MANUAL TRANSMISSION     7B1-57 

4.  OIL LEAKAGE 

 

Checkpoint  

Trouble 

Cause 

 

Countermeasure 

 

Gear oil

Replace the gear oil

Improper gear oil

Drain plug and/or filler plug

Tighten the plug(s) and

replenish the oil

Drain the oil to the correct

level

Loose plug(s)

Oil level too high

OK

NG

NG

NG

OK

OK

Oil level

Rear cover oil seal

Air breather

Replace the oil seal

Install the air breather

Replace the air breather

Worn or scratched oil seal

Air breather not installed

Air breather clogged

Front cover oil seal

Replace the oil seal

Replace the gasket(s)

Worn or scratched oil seal

Defective or improperly

installed gasket(s)

OK

NG

NG

NG

NG

OK

OK

Gaskets