2007 ISUZU KB P190 oil

FRONT WHEEL DRIVE 4C1-67
4. NOISES IN FRONT AXLE
Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil
NG
Replace the wheel bearing
Replace the pinion shaft
bearing
Replace the ring gear pinion
gear or side gear
Replace the gear oil
W heel bearingWorn
Pinion shaft bearingWorn
W orn or chipped
W rong or poor grade gear oil
Ring gear, pinion gear or side
gear
Adjust the backlashDrive pinion to ring gear
backlashToo much or too little backlash
NG
NG
NG
NG
NG
OK
OK
OK
OK
Oil level
Tighten or replaceDifferential bearingLoose or worn
NG
OK



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ISUZU KB P190 2007

4C1-72 FRONT WHEEL DRIVE
ILLUSTRATION PART NO. PART NAME
9-8522-
1274-0
(J-24252) Inner bearing outer race installer
5-8840-2085-0
(J-2 1777-42) Pilot
5-8840-2089-0
(J-23597-9) Nut & bolt
5-8840-2087-0
(J-23597-7) Gauge plate
5-8840-0
126-0
(J-800 1) Dial indicator
5-8840-0
128-0
(J-23597- 1) Arbor
5-8840-2088-0
(J-23597-8) Disc (2 pcs. required)
9-8522-
1165-0
(J-6 133-0 1) Pinion bearing installer (for 4W D)
9-8522-
1275-0
(J-24250) Pinion oil seal installer

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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-73
ILLUSTRATION PART NO. PART NAME
9-8522-
1164-0
(J-24244) Side bearing installer

5-8840-2852-0
Outer bearing installer
(for 2W D)
5-8522-0054-0
(J-290 15) Inner bearing installer
(for 4W D)
5-8840-2853-0
Hub oil seal installer
(for 2W D)

5-8840-2
117-0
(J-36827) Hub nut wrench

5-8840-2
119-0
(J-36829) Inner bearing installer (for 4W D)
5-8840-2854-0
Oil seal installer (for 4W D)
5-8840-2789-0
ABS sensor rotor installer
9-8522-
1270-0 Inner bearing installer (for 2W D)


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ISUZU KB P190 2007

4C2-4 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM AND ASSOCIATION PARTS








RTW 440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.


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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-5



Disassembly
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear





412RW 017
10. Snap Ring
Remove snap ring from front axle case by using a snap ring pliers.
11.Inner Shaft
Take out inner shaft from front axle case.





412RW 016
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring pliers.





412RW 015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and press.
Remover : 5-8840-2197-0
NOTE:
Be careful not to damage the shaft.

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ISUZU KB P190 2007

4C2-6 SHIFT ON THE FLY SYSTEM





412RS045
14.Needle Bearing
Remove needle bearing from inner shaft by using a special tool.
Remover : 5-8840-0027-0
Sliding hammer : 5-8840-0084-0
NOTE:
Be careful not to damage the shaft.
15.Oil Seal
Remove oil seal from front axle case.
NOTE:
Be careful not to damage the front axle case.

Inspection and Repair
Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.

Visual Check
• Check and see if the inner shaft has such
abnormalities as wear and damage.








412RW 014





412RS008
•
W hen inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormalit
y
in its gear part (a slide with sleeve), replace the shaft.


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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-7















412RS026
Inner Shaft Run-Out
W ith both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit) mm (in)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.






RTW 440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smooth less is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smooth less, replace the
needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or checking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.











412RW 011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smooth less is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.






412RW 022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

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ISUZU KB P190 2007

4C2-8 SHIFT ON THE FLY SYSTEM




RTW 440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, o
r
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as smooth less when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.





RTW 440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)




RTW 440SH000501




RTW 440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or othe
r
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.

State Port 3Port 4Port 1, 2
Conducting Function
A
+ −
−−
−
C
B −
−−
−
+ × D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

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ISUZU KB P190 2007