2007 ISUZU KB P190 oil

CLUTCH 7C-43
1. CLUTCH SLIPPAGE

Checkpoint Problem Countermeasure


Adjust the push rod play

No push rod play in the master
cylinder

NG
Clutch pedal free play

Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal

Clean the related parts and/or
replace the facing


Repair or replace the
transmission front cover


Defective transmission front
cover oil seal

Continued on the next page

Grease or oil adhering to the
facing

Too much grease


Transmission front cover
unevenly worn


Release bearing

NG
NG
NG
OK
OK OK


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-44 CLUTCH
Checkpoint Problem Countermeasure

Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG
NG
OK
OKGrease or oil adhering to the
facing
Clutch diaphragm springReplace the clutch pressure
plate assemblyW eak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG
NG
OKFacing
Continued from the previous page



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CLUTCH 7C-47
3. CLUTCH SHUDDER

Checkpoint Problem Countermeasure

Grease or oil adhering to the
facing
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Replace the pressure plate
assembly
Defective transmission front
cover oil seal
Pressure plate unevenly wornPressure plate
Clean the related parts and/or
replace the facing
Tighten the connections
Repair or replace the
applicable parts
Too much grease
Poorly connected components
causing looseness and
abrasion
OK
NG
NG
NG
NG
OK
Power train
Clean and grease the spline
contact surface
Insufficient grease on the
spline contact surface of the
splined hub
Driven plate
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Corrosion or step wear on the
top gear shaft spline
Defective crankshaft rear oil
seal
OK NG
NG
NG
OK
Continued on the next page

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-50 CLUTCH
5. OIL LEAKAGE

Checkpoint Problem Countermeasure


Replace the body sub
assembly
W eak or damaged piston cup

NG


Tighten the oil pipe


Tighten the oil pipe connection


Tighten the fluid pipe and/or
hose connections


Fluid reservoir

Loosely connected oil pipe


Loosely connected oil pipe


Master cylinder fluid pipe and
hose

Loosely connected fluid pipe
and/or hose


Slave cylinder oil pipe


Replace the piston cup

Slave cylinder

W eak or damaged piston cup

NG
NG
NG
NG
OK
OK
OK
OK

Master cylinder





BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

TRANSFER CASE 7D-1
SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service Precaution ......................................................................................................... 7D – 2
General Description ........................................................................................................ 7D – 3
On-Vehicle Service ......................................................................................................... 7D – 4
Transfer Case Oil Level ............................................................................................... 7D – 4
Transfer Case Oil Change ........................................................................................... 7D – 5
Transfer Case Front Oil Seal ...................................................................................... 7D – 6
Transfer Case Rear Oil Seal ........................................................................................ 7D – 9
Transfer Case Assembly ................................................................................................ 7D – 11
Transfer Case Assembly and Associated Parts ........................................................ 7D – 11
Removal ....................................................................................................................... . 7D – 12
Installation .................................................................................................................. .. 7D – 12
Transfer Control Unit ...................................................................................................... 7D – 16
Removal ....................................................................................................................... . 7D – 17
Installation .................................................................................................................. .. 7D – 17
Transfer Disassembly .................................................................................................... 7D – 18
Removal ....................................................................................................................... . 7D – 18
Inspection and Repair ................................................................................................. 7D – 27
Inspection and Repair (Transfer Case Assembly) .................................................... 7D – 27
Reassembly .................................................................................................................. 7 D – 31
Main Data and Specifications ........................................................................................ 7D – 41
Special Tools ................................................................................................................ 7D – 44


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7D-4 TRANSFER CASE
On-Vehicle Service
Transfer Case Oil Level

RTW 67DMF000101
Legend

(1) Transfer Case
(2) Filler Plug and O-ring

Removal
1. Disconnect the battery ground cable.
2. Rise and support the vehicle with suitable stands.
3. Remove the filler plug and O-ring.
4. Check the oil level reaches the filler hole.
5. If the oil level is low, fill the transfer oil (5W -30) o
r
equivalent to the transfer through the filler hole.

Installation

1. Replace the filler plug and O-ring tighten it to the
specified torque.
Filler plug torque: 39 N ⋅
⋅⋅
⋅
m (4.0 kgf ⋅
⋅⋅
⋅
m/29 lb ⋅
⋅⋅
⋅
ft)
2. Lower the vehicle to the ground.
3. Connect the battery ground cable.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

TRANSFER CASE 7D-5
Transfer Case Oil Change

RTW 67DMF000201
Legend

(1) Transfer Case
(2) Drain Plug and O-ring
(3) Filler Plug and O-ring

Removal

1. Disconnect the battery ground cable.
2. Rise and support the vehicle with suitable stands.
3. Place a suitable sized drain tray under the transfe
r
case.
4. Remove the drain plug and O-ring drain the transfe
r
case oil.
5. Remove the filler plug.

Installation

1. Replace the drain plug and O-ring to the transfer case
and tighten it to the specified torque.
Drain plug torque: 39 N ⋅
⋅⋅
⋅
m (4.0 kgf ⋅
⋅⋅
⋅
m/29 lb ⋅
⋅⋅
⋅
ft)
2. Fill the specified volume of the transfer oil (5W -30) o
r
equivalent to the transfer case through the filler hole.
Transfer oil volume: 1.3 lit. (1.37 US qt)
3. Replace the filler plug and O-ring tighten it to the specified torque.
Filler plug torque: 39 N ⋅
⋅⋅
⋅
m (4.0 kgf ⋅
⋅⋅
⋅
m/29 lb ⋅
⋅⋅
⋅
ft)
4. Lower the vehicle to the ground.
5. Connect the battery ground cable.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7D-6 TRANSFER CASE
Transfer Case Front Oil Seal
Transfer Front Oil Seal and Associated Parts

RTW 67DMF000301
Legend
(3) O-ring
(1) Front Propeller Shaft (4) Output Flange
(2) End Nut (5) Front Oil Seal

Removal

1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Place a suitable sized drain tray under the transfe
r
case.
4. Remove the drain plug and drain the transfer case oil.
5. Remove the filler plug.
6. Remove the front propeller shaft.
7. Use a flange holder (5-8840-0133-0) to remove the end nut from the front output shaft then remove the
O-ring and the output flange.
8. Remove the front oil seal from the front cover.




RTW 77DSH000201

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007