Isuzu KB P190. Manual - part 1182

 Manual Transmission (MUX)    7B1-9

• Apply alignment marks on the flange at the

differential side.

9. Remove the front propeller shaft. (4x4 model)

• Apply alignment marks on the flange at both

front and rear side.

10. Disconnect the harness connectors and clips on

the transmission.

Legend

1. Neutral switch connector
2. Clutch damper valve connector

 

Legend

3. Clip
4. Reverse switch connector
5. 1st switch connector

 

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7B1-10    Manual Transmission (MUX) 

Legend

6. Car speed sensor conector
7. Clip
8. 2-4 switch connector (4x4 model)
9. Neutral switch connector (4x4 model)

10. Transfer actuator connector (4x4 model)

 

11. Remove the harness bracket fixing bolt on the

transmission left side.

12. Remove the slave cylinder fixing bolts.

13. Remove the fuel pipe bracket fixing bolt and

disconnect fuel pipe clip.

14. Remove the clutch housing cover and clutch

bearing dust cover.

15. Use the remover 5-8840-2291-0 to disconnect the

clutch release bearing from the clutch pressure
plate.

a. Pull the shift fork toward the transmission to

press the clutch release bearing against the
clutch.

b. Insert the remover between the wedge collar

and the release bearing.

c. Turn the remover to separate the release

bearing.

Notice:
Be sure not to insert the remover between the wedge
collar and the clutch.

Legend

1. Release bearing
2. Pressure plate assembly
3. Bearing remover : 5-8840-2291-0
4. Wedge collar

 

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 Manual Transmission (MUX)    7B1-11

Legend

1. Correct procedure
2. Wrong procedure
3. Front
4. Wedge collar
5. Clutch release bearing
6. Bearing remover : 5-8840-2291-0

 

• When clutch release bearing cannot be

removed (For instance, transformation of
wedge collar, and other reasons), remove
the shift fork in order of the following with a
tool of L-type (2) as shown in figure.
1) Remove the snap pin (1).
2) Remove the shift fork pin (4).
3) Remove the shift fork (3).

Notice:
Do not remove by this method usually.
The clutch release bearing or wedge collar might be
damaged with the input shaft of transmission at
removed the transmission because the clutch release
bearing is adhered to clutch.

16. Support transmission assembly (4x2 model) or

transmission & transfer assembly (4x4 model) with
a transmission jack.

17. Remove the transmission rear mount nuts fixing on

crossmember from the transmission crossmember.

18. Remove the transmission crossmember by

removing four fixing bolts and nuts.

19. Remove the transmission rear mount.

20. Remove the starter assembly.

21. Disconnect harness clips on the transmission left

side.

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7B1-12    Manual Transmission (MUX) 

22. Remove the transmission retaining nuts and bolts.

Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.

23. Remove the transmission-transfer fixing bolts and

nut, and disassemble the transfer from the
transmission. (4x4 model)

Installation

1. Apply grease (BESCO L-2 or equivalent) on the

splined portion of the output shaft.

2. Connect the transfer to the transmission. (4x4

model)

3. Install the transmission-transfer fixing bolts and

nut, and tighten them to the specified torque. (4x4
model)

Torque: 41 N

⋅m (4.2 kgf⋅m/30 lb⋅ft)

4. Apply a thin coat of molybdenum disulfide grease

on the splined portion of the input shaft spline.

5. Slowly operate the transmission jack until the front

of transmission is aligned with the rear of the
engine.

6. Align the input shaft spline with the clutch driven

plate spline.

7. Install the transmission assembly (4x2 model) or

the transmission & transfer assembly (4x4 model)
to the engine.

• Tighten the transmission bolts to the specified

torque.

Torque: 76 N

⋅m (7.7 kgf⋅m/56 lb⋅ft)

8. Apply a force 69 N

⋅m (7 kgf⋅m/51 lb⋅ft) to the tip of

the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.

Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N

⋅m (2.6 kgf⋅m/19 lb⋅ft). If

the shift fork will not move, then they are securely
engaged.

9. Connect harness clips on the transmission left

side.

10. Install the starter assembly.

• Tighten the starter bolts to the specified torque.

Torque: 94 N

⋅m (9.6 kgf⋅m/69 lb⋅ft)

11. Install the transmission rear mount to the

transmission.

• Tighten the transmission rear mount bolts to the

specified torque.

Torque: 50 N

⋅m (5.1 kgf⋅m/37 lb⋅ft)

12. Install the transmission crossmember by removing

four bolts and nuts.

• Tighten the transmission crossmember bolts to

the specified torque.

Torque: 67 N

⋅m (6.8 kgf⋅m/49 lb⋅ft)

13. Install the transmission rear mount nuts fixing on

crossmember from transmission crossmember.

• Tighten the transmission rear mount nuts to the

specified torque.

Torque: 52 N

⋅m (5.3 kgf⋅m/38 lb⋅ft)

Remove the transmission jack from transmission
side.

14. Install the fuel pipe bracket bolt and connect fuel

pipe clip.

• Tighten the fuel pipe bracket bolt to the

specified torque.

Torque: 76 N

⋅m (7.7 kgf⋅m/56 lb⋅ft)

15. Install the slave cylinder fixing bolts.

• Tighten the slave cylinder bolts to the specified

torque.

Torque: 43 N

⋅m (4.4 kgf⋅m/32 lb⋅ft)

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