Isuzu KB P190. Manual - part 1187

 Manual Transmission (MUX)    7B1-29

42. In order to protect the front oil seal lip, wrap a tape

around the spline portion of the input shaft.

43. Install the intermediate plate assembly with gear

(1) to the front case.

• Apply recommended liquid gasket (LOCTITE

FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.

44. Install the magnet (1).

45. Remove the straight plug (1) from the rear case.

46. Install the rear case assembly.

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3

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7B1-30    Manual Transmission (MUX) 

• Apply recommended liquid gasket (LOCTITE

FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.

Notice:
Be careful of the insertion position of the rear gutter.

47. Check whether the rear gutter (1) appears from the

straight plug hole.
Install the new straight plug.

• Never reinstall the used straight plug.

• Tighten the straight plug to the specified torque.

Torque: 34 N

⋅m (3.5 kgf⋅m/25 lb⋅ft)

Notice:

• If the rear gutter does not appear from the straight

plug hole, the rear gutter is not in the right position.
Remove and reinstall the rear case.

• When there is no rear gutter in the right position, it

becomes lubriciously poor.

48. Install the rear case bolts.

• Tighten the rear case bolts to the specified

torque.

Torque: 23 N

⋅m (2.3 kgf⋅m/17 lb⋅ft)

49. Install the output rear bearing inner race.

50. Use the snap ring selector 5-8840-2849-0 to select

the new output shaft snap ring.

• Never reinstall the used snap ring.

a. Place the snap ring selector on the output rear

bearing.

b. Join the bolt (2) to the output shaft (4).

c. Adjust the end of both grips (3) with a bottom of

spline and tighten both grips evenly.

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 Manual Transmission (MUX)    7B1-31

d. Tighten the nut (1) till the height of spring

reaches 29 mm (1.142 in) (a).

e. Turn the output shaft rear bearing inner race (6)

and the snap ring selector (5) together 16 times
or more in order to make the output shaft rear
bearing inner and outer race fit well.

f. Try to insert gauges (7) of six different

thickness in turn to the snap ring groove of
output shaft.
Select the thickest gauge that could be
inserted.

g. The thickness of the selected gauge shows the

thickness of the snap ring to be installed.

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7B1-32    Manual Transmission (MUX) 

Snap Ring Availability

51. Install the new snap ring to the output shaft.

• Never reinstall the used snap ring.

52. Install the speedometer drive gear. (4x2 model)

53. Install the gear set clip. (4x2 model)

54. Install the end cover assembly.

• The gasket must be assembled. (4x2 model)

• Apply recommended liquid gasket (LOCTITE

FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below. (4x4
model)

• Tighten the end cover bolts to the specified

torque.

Torque: 23 N

⋅m (2.3 kgf⋅m/17 lb⋅ft)

55. Install the speedometer driven gear and plate. (4x2

model)

56. Install the control rod detent assembly.

• Tighten the three detent assemblies to the

specified torque.

Torque: 30 N

⋅m (3.1 kgf⋅m/22 lb⋅ft)

57. Install the new 5th detent assembly and new

reverse detent assembly.

• Never reinstall the used detent assembly.

• Tighten the three detent assemblies to the

specified torque.

Torque: 30 N

⋅m (3.1 kgf⋅m/22 lb⋅ft)

58. Install the two harness brackets.

Torque: 8N

⋅m (0.8 kgf⋅m/69 lb⋅in)

59. Install the reverse switch (Connector color Brown),

1st switch (Connector color Gray) and neutral
switch (Connector color Brown) with gasket.

• Tighten the three switches to the specified

torque.

Torque: 39 N

⋅m (4.0 kgf⋅m/29 lb⋅ft)

60. Install the control unit block by performing the

following steps.

a. Push the control unit block ahead.

b. Install the control unit block.

c. Install the new taper bolt.

• Never reinstall the used taper bolt.

• Tighten the taper bolt to the specified

torque.

Torque: 47 N

⋅m (4.8 kgf⋅m/35 lb⋅ft)

Important:

• Must be checked no flaw to taper bolt.

• Must be checked no jam of foreign body before

assembled.

• Must be checked same position upper surface of the

taper bolt and the control unit block after
assembled.

61. Install the two dowels and quadrant box.

• Apply recommended liquid gasket (LOCTITE

FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.

• Tighten the quadrant box bolts to the specified

torque.

Torque: 23 N

⋅m (2.3 kgf⋅m/17 lb⋅ft)

62. Remove the tape from the spline portion of the

input shaft.

Thickness

Identification color

2.1 mm(0.083 in)

White

2.2 mm(0.087 in)

Blue

2.3 mm(0.091 in)

Green

2.4 mm(0.094 in)

Yellow

2.5 mm(0.098 in)

Orange

2.6 mm(0.102 in)

Black

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