Isuzu KB P190. Manual - part 1179

7B1-110     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     7B1-111 

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

 

 

7B1-112     MANUAL TRANSMISSION 

Special Tools (4

××××4) 

 

ILLUSTRATION 

TOOL NO. 

TOOL NAME 

 ILLUSTRATION 

TOOL NO. 

TOOL NAME 

 

5-8840-2158-0 

(J-37222) 

Mainshaft retainer 

remover 

 

 

5-8840-2159-0 

(J-37223) 

Mainshaft end bearing 

installer 

 

5-8840-2027-0 

Puller 

 

 

5-8840-0015-0 

(J-22912-01) 

Bearing 

 remover/installer 

 

5-8840-2160-0 

(J-37224) 

Holding fixture 

 

 

 

5-8522-0050-0 

(J-29769) 

Rear case oil seal 

installer 

 

5-8840-0003-0 

(J-3289-20) 

Holding fixture base 

 

 

5-8840-0026-0 

(J-26540) 

Front cover oil seal 

installer 

 

5-8840-2156-0 

(J-37219) 

Mainshaft nut wrench 

 

 

9-8522-1165-0 

(J-6133-01) 

Mainshaft collar remover

 

5-8840-0047-0 

(J-37225) 

Tork bit wrench 

(T– 45) 

 

 

5-8840-0007-0 

(J-8092) 

Grip 

 

MANUAL TRANSMISSION     7B1-113 

ILLUSTRATION 

TOOL NO. 

TOOL NAME 

 

 

 

 

5-8840-2194-0 

Bearing installer