2007 ISUZU KB P190 oil

TRANSFER CASE 7D-7
Installation
1. Thoroughly clean around the oil seal bore in the case
and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.
3. Tap the oil seal in to place, use an oil seal installe
r
(5-8840-2785-0) and a soft hammer.



RTW 77DSH000301
4. Install the output flange to the front output shaft.
5. Apply the engine oil to the new O-ring and install it to the front output shaft.
6. Secure the output flange with a flange holde
r
(5-8840-0133-0).
7. Install the new end nut and tighten them to specified torque.
Front coupling driver fixing nut torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)

8. Use a punch (5-8840-2293-0) to caulk the end nut.




226R300012




RUW 34DSH000301
Legend
(1) MAX 26mm (1.02in)
(2) MIN 4mm (0.16in)


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ISUZU KB P190 2007

7D-8 TRANSFER CASE
9. Install the drain plug to the transfer case and tighten it
to the specified torque.
Drain plug torque: 39 N ⋅
⋅⋅
⋅
m (4.0 kgf ⋅
⋅⋅
⋅
m/29 lb ⋅
⋅⋅
⋅
ft)
Transfer oil volume: 1.3 lit. (1.37 US qt)
10. Install the filler plug and tighten it to the specified torque:
Filler plug torque: 39 N ⋅
⋅⋅
⋅
m (4.0 kgf ⋅
⋅⋅
⋅
m/29 lb ⋅
⋅⋅
⋅
ft)
11. Install the front propeller shaft.
Propeller shaft bolts torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
12. Lower the vehicle to the ground.
13. Connect the battery ground cable.



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ISUZU KB P190 2007

TRANSFER CASE 7D-9
Transfer Case Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts

220R300018
Legend

(1) Rear Propeller Shaft
(2) Rear Oil Seal

Removal

1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Remove the rear propeller shaft.
4. Remove the oil seal from the transfer case.

Installation
1. Thoroughly clean around the oil seal bore in the
transfer case and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.


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ISUZU KB P190 2007

7D-10 TRANSFER CASE
3. Tap an oil seal in to place, use an oil seal installer
5-8840-2786-0 and a soft hammer.





RTW 77DSH000401




220R300021
4. Install the rear propeller shaft.
Propeller shaft bolts torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
5. Lower the vehicle to the ground.
6. Connect the battery ground cable.



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ISUZU KB P190 2007

7D-18 TRANSFER CASE
Transfer Disassembly



RTW 67DLF000101
Legend

(1) Transfer Case Speedometer Bushing, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut
(8)
(M/T: MUA, MUX, A/T: JR405E, AW 30-40LE)
(3) Stoneguard (9) Speed sensor (M/T: AR-5, A/T: 4L60-E)

(4) Detent Plug, Spring and Detent Ball (10) Transfer Actuator (Diesel Engine)
(5) 2-4 Switch ASM (11) Transfer Actuator (Gasoline Engine)
(6) Switch Bracket (12) Breather Hose
(7) Neutral Switch ASM (13) Heat Protector (Gasoline Engine)

Removal

1. Remove the stoneguard.
2. Remove the drain plug from the transfer case to drain
the oil.
3. Remove the parts listed below.
• Speedometer bushing, plate, and speedomete
r
driven gear (M/T: MUA, MUX, A/T: JR405E,
AW 30-40LE)
• Speed sensor (M/T: AR-5, A/T: 4L60-E)

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ISUZU KB P190 2007

7D-20 TRANSFER CASE
7. Remove the parts listed below from the rear cover.
• H-L sleeve
• H-L shift assembly
• 2-4 sleeve, synchronizer key, and front
synchronizer spring (do not remove the rear
spring)
• 2-4 shift assembly
• Shift drum and shift shaft
• Sun gear needle bearing

260R300001












8. Remove the oil pump strainer fixing bolts from the
rear cover.
9. Compress the retaining ring at the rear of the chain.
Strike the rear end of the main shaft with a plastic
hammer to remove the main shaft, transfer chain, and
front output shaft assembly from the rear cover. Be
careful not to damage the oil pump strainer.

226R30001

Legend

(1) Sun Gear Needle Bearing
(2) H-L Sleeve
(3) 2-4sleeve, synchronizer key, and front synchronizer spring
(4) 2-4 Shift ASM
(5) Shift Shaft
(6) H-L Shift ASM
(7) Shift Drum

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ISUZU KB P190 2007

TRANSFER CASE 7D-21
10. Remove the transfer chain and the front output shaft
from the main shaft.
11. Remove the main shaft snap ring.
12. Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13. Remove the sprocket snap ring.
14. Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.


RTW 37DMF000101
Legend
(8) Thrust W asher
(1) Rear synchronizer spring
(9) Sprocket Snap Ring
(2) Block Ring
(10) Oil Pump ASM
(3) Outside Ring
(11) Oil Pump Retaining Ring
(4) Inside Ring
(12) Retaining Ring
(5) Drive Sprocket
(13) Ball Bearing
(6) Transfer Chain (14) Speedometer Drive Gear
(7) Front Output shaft (15) Main Shaft Snap Ring


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ISUZU KB P190 2007

TRANSFER CASE 7D-23


23. Remove the retaining ring (spiral type) together with
the internal gear and the damper ring.

226R300004






24. Remove the snap ring.
25. Use a press to remove the front output shaft ball
bearings.
26. Remove the oil pump wire snap ring from the rear
cover.

27. Use a sliding hammer (5-8840-0084-0) and a needle
bearing replacer (5-8840-2788-0) to remove the
needle bearing from the front output shaft.


P1010023
Legend
(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring

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ISUZU KB P190 2007