2007 ISUZU KB P190 oil

7D-26 TRANSFER CASE
2-4 shift reassembly
1. Install the shift block assembly to the shift rod.
2. Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.

226R300015
3. Install the spring.
4. Install the shift arm.
5. Compress the spring and install the snap ring.
6. Install the guide roller.

Oil pump disassembly
1. Remove the clamps securing the screen.
2. Remove the screen.
3. Remove the clamps securing the hose.
4. Remove the hose.
NOTE: To maintain and protect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Oil pump reassembly

1. Tighten the clamps to secure the hose.
2. Tighten the clamps to secure the screen.
NOTE: Be careful in the direction of clamps.

RTW 37DSH000101
Legend
(1) Oil Pump Assembly
(2) Clamp
(3) Hose
(4) Screen Assembly



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ISUZU KB P190 2007

TRANSFER CASE 7D-27
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. W ash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign material
are removed from the surfaces of every part. Appl
y
compressed air to each oil feed port and channel in
each case half to remove any obstructions or cleaning
solvent residue.

Inspection and Repair (Transfer Case
Assembly)
W hen wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or replaced. W ash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or
residual detergent.

Chain
• Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
• If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket
• Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
• If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear
• Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
• Remove minor flaws or scratches with oil stone. I
f
excessive wear or damage is observed, replace the
part.

2-4 and Neutral Switch

• Check the continuity of 2-4 and Neutral switch.
If defects are observed, replace the 4H and 4L switch.




221R300001
261R300003
Switch
Stroke 2-4 Switch
Signal Neutral Switch

Signal
Terminal
1 to 2 Terminal
1 to2
1 Open Close
2 Close Open



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ISUZU KB P190 2007

7D-28 TRANSFER CASE
Oil Pump
• Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play
• Set a dial indicator to the clutch hub to be measured.
• Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
• If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard: 0-0.1 mm (0-0.004 in)
Limit: 0.2 mm (0.008 in)

226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. W ash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.

Ball Bearing Play

1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit: 0.2 mm (0.008 in)

226R3043

Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
• Teeth for wear, scuffs, nicks, burrs or breaks.
• Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
• If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.


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ISUZU KB P190 2007

TRANSFER CASE 7D-31
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is reassembled.
1. Use an oil seal installer (5-8840-2785-0) to press the
new input shaft and/or front output shaft oil seals into
place (If replacement is required).






RTW 77DSH000301
2. Use a press to install the ball bearings to the front
output shaft. Be sure that the bearings are full
y
inserted and then install the snap ring.
3. Install the damper ring and the internal gear to the
transfer case. Be sure that the damper ring is
between the internal gear and the case.

226R300004






Note the direction of the dumper ring installation as
figure.

226R300025
Legend

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

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ISUZU KB P190 2007

7D-34 TRANSFER CASE
14. Insert the H-L sleeve into the main shaft.


226R300023
Legend

(1) H-L Sleeve
(3) Synchronizer Key and Key Spring

(2) 2-4 Sleeve


15. Install the sleeve to the H-L shift assembly.
16. Install the sleeve to the 2-4 shift assembly.
17. Coat the area around each of the shift assembl
y
insertion holes (transfer case) with transfer oil.
18. Install the main shaft together with the H-L shift
assembly and the 2-4 shift assembly to the shift drum.



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ISUZU KB P190 2007

TRANSFER CASE 7D-35
19. Align the shift shaft splines with the shift drum and
install the shafts to the drum.


RTW 320MF000201
Legend

(1) H-L Sleeve and Shift ASM
(3) Shift Shaft

(2) 2-4 Sleeve ASM with Main Shaft and Shift ASM (4) Shift Drum


NOTE: Be careful in the direction of an assembly.

P1010041/020124
20. Coat the main shaft with oil.
21.
Align the block ring, the outside ring, and the inside
ring with the 2-4 hub assembly and install them.
22. Assemble the sprocket, transfer chain, and front
output shaft.
23. Install the sprocket, transfer chain, and front output
shaft to the main shaft and the transfer case.


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ISUZU KB P190 2007

7D-36 TRANSFER CASE
24. Align the sprocket thrust washer with the main shaft
groove and install it.

226R300009

25. Select a snap ring that will allow minimum axial play.
Insert it to the main shaft installation groove.
mm (in)
Snap ring thickness Identification color
2.15 (0.085) Red
2.10 (0.083) Not colored
2.05 (0.081) Blue
2.00 (0.079) White

226R300008


Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) Sprocket
(5) Transfer Chain
(6) Front Output Shaft
(7) Thrust W asher
(8) Snap Ring

26. Measure the snap ring external diameter. If the
measured diameter is outside the specified range, a
larger or smaller snap ring must be used.
Snap ring outside diameter (Standard):
53.0 ±
±±
±
0.5 mm (2.09 ±
±±
±
0.02 in)
27. Position the rear cover so that its mating surfaces are
facing up.
28. Use a press and an installer (5-8840-2783-0) to install
the front output shaft needle bearing. The installe
r
must be aligned with the bearing manufacturer's
name (stamped into the bearing).





29. Install the oil pump wire snap ring to the rear cover.


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ISUZU KB P190 2007

TRANSFER CASE 7D-37
226R300005



30. Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31. Use a press and an installer (9-8522-1268-0) to install
the rear output shaft ball bearings. Do not drive the
ball bearings into place with a hammer.





32. Install the rear output shaft retaining ring.
33. Place the oil pump in its specified position.
34. Secure the oil pump strainer to the rear cover and
tighten the bolts to the specified torque.
Oil pump and rear cover bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)


226R300010










35.
Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
Legend

(1) Oil Pump Assembly
(2) W ire Snap Ring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend
(1) W ire Snap Ring

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ISUZU KB P190 2007