2007 ISUZU KB P190 torque

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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REAR AXLE 4B-25
b. Tighten the nut to the specified torque.
Torque:
φ220mm : 2.7 N ⋅m (0.28 kgf ⋅m/24 lb ⋅in)
φ194mm : 2.3 N ⋅m (0.23 kgf ⋅m/20 lb ⋅in)



425RW 030

c. Clean the side bearing bores. Place discs and
dial indicator on to arbor, and place tool into
position in side bearing bores. Install and
tighten the bearing caps to the specified
torque.
Torque : φ220mm : 108N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 94N ⋅m (10 kgf ⋅m/72 lb ⋅ft)

425RW 031
Legend
φ
φφ
φ
220mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2166-0
3. Disc (2 pcs.) : 5-8840-2167-0
4. Arbor : 5-8840-0128-0
φ
φφ
φ
194mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2087-0
3. Disc (2 pcs.) : 5-8840-2088-0
4. Arbor : 5-8840-0128-0



Note :
The scale on the dial indicator (5-8840-0126-0) is
inch unit.
d. Set the dial indicator 5-8840-0126-0 to “0”.
Place it on the mounting post of the gauging
arbor with the contact button touching the
indicator pad. Force the dial indicato
r
downward until the needle has made a hal
f
turn clockwise. Tighten down the dial indicato
r
in this position.




425RS020
Legend
1. Dial Indicator
2. Gauging Arbor
3. Plunger
4. Gauge Plate


e. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicato
r
shows the greatest deflection. At this point,
once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.

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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-29
Starting torque :
φ220mm : 0.7-1.3 N ⋅m
(0.07-0.13 kgf ⋅m/6-11 lb ⋅in)
φ194mm : 0.7-1.1 N ⋅m
(0.07-0.11 kgf ⋅m/6-10 lb ⋅in)
Note :
• Do not overtighten or loosen and then
retighten the nut.
• Pinion nut torque will be in the range of 245-
294 N ⋅
⋅⋅
⋅
m (25-30 kgf ⋅
⋅⋅
⋅
m/181-217 lb ⋅
⋅⋅
⋅
ft) ( φ
φφ
φ
220mm)
and 177-275 N ⋅
⋅⋅
⋅
m (18-28 kgf ⋅
⋅⋅
⋅
m/130-203 lb ⋅
⋅⋅
⋅
ft)
( φ
φφ
φ
194mm).
425RW 018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.



RTW 54BSH000901

11. Adjust ring gear backlash. a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010

b. Insert the differential cage assembly with bearing outer races into the side bearing bores
of the carrier.


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ISUZU KB P190 2007

4B-32 REAR AXLE
16. Tighten the bolt to the specified torque.
Torque :
φ220mm : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 98 N ⋅m (10 kgf ⋅m/72 lb ⋅ft)


425RS036
• Measure the amount of run-out of the ring gear at
its rear face. It should be 0.05 mm (0.002 in) o
r
less
Gear Tooth Contact Pattern Check and Adjustment
1.
Apply a thin coat of Prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring gea
r
teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.





425RS038
Legend
1. Heel
2. Toe
3. Concave Side(Coast)
4. Convex Side(Drive)



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4B-36 REAR AXLE
425R300010

Play in splines between the side gear and axle shafts. mm(in)
Standard Limit
φ220mm 0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)
φ
194mm 0.08 - 0.36
(0.003 - 0.014) 0.5 (0.02)
425L100014

Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of
thread to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as illustrated.
Torque : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)



425RW 033


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ISUZU KB P190 2007