2007 ISUZU KB P190 air condition

REAR SUSPENSION 3D-11
LEAF SPRING ASSEMBLY

F03L100004

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.




RTW 430SH000101
2. Apply a setting mark across the springs before
disassembling the leaf spring assembly.

F03L100006
3. Use a bench press and remove the center bolt.
• Discard center bolt and install a new one.

465R300001
4. Disassemble the leaf spring assembly.


Inspection and Repair
Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and repair or
replace if necessary.


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ISUZU KB P190 2007

3E-8 WHEELS AND TIRES
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.




Visual Check
Inspect all disassembled parts for wear, damage or other
abnormal conditions.
















Measure Wheel Runout
mm (in)
Wheel Type Radial Lateral
14 inch Steel
15 inch Steel Less than 1.0
(0.04) Less than 1.0
(0.04)
15 inch Alumi
16 inch Alumi Less than 0.4
(0.016) Less than 0.55
(0.022)

If the measured value exceeds the specified limit, the wheel
must be replaced.



Balancing Wheel and Tire
On-vehicle Balancing
On-Vehicle balancing methods very with equipment and tool
manufacturers. Be sure to follow each manufacturer’s
instructions during the balancing operation.
Off- vehicle Balancing
Most electronic off-vehicle balancers are more accurate than
the on-vehicle spin balancers. They are easy to use and give a
dynamic balance. Although they do not correct drum or disc
imbalance (as the on-vehicle spin balancing does), they are
very accurate.



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ISUZU KB P190 2007

PROPELLER SHAFT 4A-15
Inspection and Repair
Make all necessary adjustment, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.





Visual Check
Inspect following parts for wear, damage, or other abnormal
conditions.
Spider
Needle roller bearing
Yoke
Flange
Center bearing
Cushioning rubber
Bracket

401RS007


Outside Diameter of Spider Pins
mm(in)
Standard Limit
17 (0.67) 16.99 (0.669)




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ISUZU KB P190 2007

PROPELLER SHAFT 4A-25
401RS028
Disassembly
1. Apply alignment marks (1) on the yokes of the universal
joint, then remove snap ring.

401RS006
2. Tap out the needle roller bearing by gently striking the
shoulder of the yoke, using a mallet or a copper hammer.
3. Make sure of proper position for reinstallation by applying setting marks, then remove spider.

Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is found
through inspection.
NOTE:
W hen any part of the journal assembly (spider, needle rolle
r
bearing) requires replacement, be sure to replace the entire
assembly.
Check the following parts for wear, damage, noise or any othe
r
abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Constant velocity joint

401RS007
Outside Diameter of Spider Pin
Standard: 17.00 mm (0.6693 in)
Limit: 16.99 mm (0.6689 in)


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ISUZU KB P190 2007

4B-14 REAR AXLE
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspections.
Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.
• Axle Shaft
Axle Shaft
W hen checking the axle shaft, pay special attention to
the splined portions and replace the shaft if distortion
or step wear is noticeable. Correct slight step wea
r
with a pencil grinder.




420RS008
Axle Shaft Run-Out
Check the shafts for bending with the use of a dial
indicator in contact with the shaft. Rotate the shaft
slowly and observe the dial indicator.
Limit mm (in
)
1.0 (0.039)
Note :
Never use heat to correct bending.











RTW 74BSH000101
Legend
a. 350 mm (13.8 in)

Axle Shaft Flange Run-Out
Check the axle shaft flange for run-out. Hold the
probe of a dial indicator in contact with the flange.
Rotate the shaft slowly and observe the dial.
Limit mm (in
)
0.08 (0.003)








RTW 74BSH000201
Legend
b. 160 mm (6.3 in)



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ISUZU KB P190 2007

REAR AXLE 4B-35
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion gear on side gear before removal of cross pin.
Backlash : φ220mm : 0.13-0.18 mm (0.005-0.007 in)
φ194mm : 0.10-0.20 mm (0.004-0.008 in)
5. Remove the cross pin by using a brass drift punch and hammer.




425RS043

6. Take out pinion gear, side gear and thrust washer.

Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:
• Ring gear, pinion gear
• Bearing
• Side gear, pinion gear, cross pin
• Differential cage, carrier
• Thrust washer
• Oil seal
Clearance between pinion gear and cross pin:
mm (in)
Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm (in)
Standard Limit
φ220mm 0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)
φ
194mm 0.03 - 0.10
(0.001 - 0.004) 0.15 (0.006)


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ISUZU KB P190 2007

4B-40 REAR AXLE
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, rust or other problems
are discovered during inspection.
Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.
• Friction disc
• Friction plate
• Spring plate
1 Sliding surface
2 Protrusion





425RS056
Pressure ring
Check the parts for damage or other abnormal
conditions.
3 Sliding surface for friction disc
If dents or damages are discovered, grind them with oil stone, and repair them with compound on
surface plate.
4 Sliding surface of pressure ring inner surface and pinion gear.
5 Sliding surface of pressure ring bore and sidegear.
6 sliding surface of pressure ring and side gear.
7 Sliding surface of pressure ring and pinion shaft.
8 Mating surface to differential cage A.
9 Burrs or dents on sliding surface of pressure ringand rear differential cage should be repaired,
using oil stone.

425RY00022

• Thrust W asher
10 Groove on side gear circumference small burrs of
dens should be repaired, using oil stone.
11 Sliding surface between side gear and thrust washer.
425RY00024

• Differential cage A and B
12 Contact surface to spring plate
13 Differential cage A and B contact surfaces to
thrust washers Small burrs or dents should be
repair, using oil stone.



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ISUZU KB P190 2007

4C1-16 FRONT WHEEL DRIVE
6. Using snap ring pliers, remove the snap ring (1) fastening
the ball retainer to the center shaft.
7. Remove ball retainer, ball guide and bellows.


8. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the UJ side).
CAUTION :
Take care not to damage the bellows during band removal.



9. Remove band (1).
10. Remove bellows.
11. Remove dust seal from UJ.
12. Remove UJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.


Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are found
through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal


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ISUZU KB P190 2007