2007 ISUZU KB P190 oil

4B-16 REAR AXLE
φ
φφ
φ
220mm
Torque : Bolt 64 N ⋅m (6.5 kgf ⋅m/47 lb ⋅ft)
Nut 44 N ⋅m (4.5 kgf ⋅m/33 lb ⋅ft)
φ
φφ
φ
194mm
Torque : Bolt 25 N ⋅m (2.5 kgf ⋅m/18 lb ⋅ft)
Nut 37 N ⋅m (3.8 kgf ⋅m/27 lb ⋅ft)
5. Axle Shaft Assembly
a. Insert new double taper roller bearing in the bearing holder with oil seal.
b. Set special tool (support stand : 9-8522-1271- 0) on a bench press.
c. Put bearing holder with bearing and oil seal and back plate on the support stand as
following illustration.
d. Insert bolts and axle shaft, aligning center o
f
holes.
e. Press fit axle shaft into double taper rolle
r
bearing.




420R300010
Legend
1. Axle shaft
2. Oil Seal
3. Bolt
4. Back Plate
5. Double Taper Roller Bearing

6. Put new retainer on the special tool 9-8522-1271-
0.
7. Press fit axle shaft with the bearing into retaine
r
and make axle shaft assembly.




420R300011
Legend
1. Axle shaft
2. Oil Seal
3. Bolt
4. Back Plate
5. Retainer
6. Double Taper Roller Bearing



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ISUZU KB P190 2007

REAR AXLE 4B-17
8. Certainly install new snap ring, use snap ring
pliers. W hen transform or damage, replace ne
w
one.




RTW 34BMH000101
Legend
1. Snap ring
2. Crevice
3. Retainer (with ABS)
Retainer (without ABS)


9. Insert a shim of sufficient thickness between
snap ring and end of retainer.

Standard 0 − 0.2 mm (0 − 0.008 in)

Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 mm (0.008 in), it
adjusts so that is may become 0.2 mm (0.008 in)
or less using shim.

Shim Pats No. Thickness

1 9-41519110- ∗ 0.18 mm (0.0071 in)

2 8-97130387- ∗ 0.50 mm (0.0197 in)

Crevice No. of shim Total
mm (in)
1 2 mm (in)
1.0(0.0394)  2 1.00(0.0394)
0.9(0.0354) 2 1 0.86(0.0339)
0.8(0.0315) 1 1 0.68(0.0268)
0.7(0.0276) 1 1 0.68(0.0268)
0.6(0.0236)  1 0.50(0.0197)
0.5(0.0197)  1 0.50(0.0197)
0.4(0.0157) 2  0.36(0.0142)
0.3(0.0118) 1  0.18(0.0071)
0.2(0.0079) 1  0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
a. Clean the mating surface of axle case and bearing holder.
b. Apply Three Bond 1215 (TB1215) o
r
equivalent on the surface of axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the specified torque.
Torque : 84 N ⋅m (8.6 kgf ⋅m/62 lb ⋅ft)
12. Install wheel cylinder and tighten the bolt to the specified torque.
Torque : 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
13. Install parking brake outer cable in back plate and inner cable in parking brake lever.


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ISUZU KB P190 2007

REAR AXLE 4B-19
17. Install brake pipe and ABS sensor and tighten it
to the specified torque.
Torque : ABS Sensor 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
Brake Pipe 16 N ⋅m (1.6 kgf ⋅m/12 lb ⋅ft)
420R30003

18. Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19. Install brake drum.
• Install propeller shaft. (Refer to Section “Rea
r
Propeller Shaft”.)
• Refill differential oil.
• Install wheel and tire.
• Lower vehicle.




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ISUZU KB P190 2007

4B-20 REAR AXLE
DIFFERENTIAL ASSEMBLY
Disassemble View
Legend
1. Bolt
2. Bearing Cap
3. Differential Cage Assembly
4. Side Bearing Outer Race
5. Side Bearing
6. Adjust Shim
7. Flange Nut
8. Flange Assembly
9. Drive Pinion Shaft Assembly

415RY00005

10. Collapsible Spacer
11. Inner Bearing
12. Adjust Shim
13. Oil Seal
14. Outer Bearing
15. Inner Bearing Outer Race
16. Outer Bearing Outer Race
17. Differential Carrier




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ISUZU KB P190 2007

4B-22 REAR AXLE


415RW 040
8. Removed flange assembly.
9. Remove the drive pinion assembly using a soft metal rod and a hammer.

425RY005

10. Remove collapsible spacer.
11. Remove the inner bearing by using separator 5- 8840-2197-0 ( φ220mm) and 5-8840-0015-0
( φ 194mm) .

φ
φφ
φ
220mm




RTW 54BSH000601
φ
φφ
φ
194mm





415R300001

12. Remove adjust shim.
13. Remove oil seal.
14. Remove outer bearing.


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ISUZU KB P190 2007

4B-24 REAR AXLE
Reassembly
1. Install outer bearing outer race by using installer
5-8840-2164-0 (φ220mm), 9-8522-1141-0 ( φ194
mm) and grip 5-8840-0007-0.

φ
φφ
φ
220mm
425L100002
φ
φφ
φ
194mm


425R300001

2. Install inner bearing outer race by using installe
r
5-8840-2163-0 ( φ220mm), 9-8522-1274-0 ( φ194
mm) and grip 5-8840-0007-0.

425L100003
φ
φφ
φ
194mm




425R300002

3.
Adjust the drive pinion mounting distance as
follows:
a.
Apply gear oil to the inner and outer drive
pinion bearing. Clean the pinion setting gauge
set. Then install the gauge set together with
the inner and outer bearings.
Install gauge plate 5-8840-2166-0 ( φ220mm)
and 5-8840-2087-0 ( φ194mm) (3), inner pilot
5-8840-0129-0 ( φ220mm) (2), stud and nut 5-
8840-0127-0 ( φ220mm) and 5-8840-2089-0
( φ 194mm) (4) and outer pilot 5-8840-2085-0
( φ 220mm and φ194mm) (1) through inner and
outer bearings.


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ISUZU KB P190 2007

4B-28 REAR AXLE
4. Place the shim on the drive pinion, then install the
inner bearing onto the pinion by using installer 9-
8522-1165-0 and a press.
Note:
Do not apply pressure to the roller cage. Apply
NOTE: pressure only to the inner race.
425L100008

5. Install collapsible spacer. Discard the used collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal.
8. Use oil seal installer 5-8840-2165-0 ( φ220mm)
and 9-8522-1275-0 ( φ194mm) to install a new oil
seal that has grease on seal lip.

φ
φφ
φ
220mm
415RW 029

φ
φφ
φ
194mm


415RW 024

9. Install flange assembly.
10. Install flange nut. a. Apply lubricant to the pinion threads.
b. Using the pinion flange holder 5-8840-0133-0, tighten the nut only enough to remove the shaft
end play.
Note :
Discard used flange nut and install new one.
415RW 040
c. Adjust pinion bearing preload.
• Measure the bearing preload by using a torque
meter and note the scale reading required to
rotate the flange.
• Continue tightening flange nut until the
specified starting torque is obtained.



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ISUZU KB P190 2007

REAR AXLE 4B-35
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion gear on side gear before removal of cross pin.
Backlash : φ220mm : 0.13-0.18 mm (0.005-0.007 in)
φ194mm : 0.10-0.20 mm (0.004-0.008 in)
5. Remove the cross pin by using a brass drift punch and hammer.




425RS043

6. Take out pinion gear, side gear and thrust washer.

Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:
• Ring gear, pinion gear
• Bearing
• Side gear, pinion gear, cross pin
• Differential cage, carrier
• Thrust washer
• Oil seal
Clearance between pinion gear and cross pin:
mm (in)
Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm (in)
Standard Limit
φ220mm 0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)
φ
194mm 0.03 - 0.10
(0.001 - 0.004) 0.15 (0.006)


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ISUZU KB P190 2007