2007 ISUZU KB P190 differential

REAR AXLE 4B-1
SECTION 4B
REAR AXLE

TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4B- 3
Torque Specifications .............................................................................................................. 4B- 4
Recommended Liquid Gasket .......................................................................................... 4B- 6
Recommended Thread Locking Agents .......................................................................... 4B- 6
Rear Axle Assembly .......................................................................................................... 4B- 7
General Description...................................................................................................... 4B- 7
Servicing ...................................................................................................................... ...... 4B- 8
Rear Axle ...................................................................................................................... ...... 4B- 9
Disassembly .................................................................................................................. 4B - 10
Inspection and Repair .................................................................................................. 4B- 14
Reassembly ................................................................................................................... 4B - 15
Differential Assembly ..................................................................................................................... 4B- 20
Disassembly .................................................................................................................. 4B - 21
Reassembly ................................................................................................................... 4B - 24
Differential Cage Assembly .......................................................................................................... 4B- 34
Disassembly .................................................................................................................. 4B - 35
Inspection and Repair .............................................................................................................. 4B- 35
Reassembly ................................................................................................................................. 4B- 37
Limited Slip Differential (LSD) .......................................................................................... 4B- 38
Disassembly ............................................................................................................................... .4B- 39
Inspection and Repair .................................................................................................. 4B- 40
Reassembly ................................................................................................................... 4B - 42
Troubleshooting............................................................................................................ 4B- 45
Special Service Tool ................................................................................................................. 4B- 56

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ISUZU KB P190 2007

REAR AXLE 4B-3
MAIN DATA AND SPECIFICATIONS
REAR AXLE
Ring gear size mm (in)φ194 (7.94) φ220 (8.66)
Rear axle type Banjo, semi-floating
Rear axle capacity N (kg/lb)18140 (1850/4079)
Rear axle case
Axle tube section

Outside diameter mm (in)80 (3.15)
Thickness mm (in)4.5 (0.118)
Final drive type Single speed
Final gear type Hypoid
Drive pinion bearing preload N⋅m (kgf ⋅cm/lb ⋅in)
Starting torque (At drive pinion flange nut) 0.6-1.1 (6.5-11.5/5.6-10.0) 0.7-1.3 (7.0-13.0/6.1-11.3)
Preload adjusting method Collapsible
Final gear backlash mm (in) 0.13-0.18 (0.005-0.007) 0.15-0.20 (0.006-0.008)
Differential carrier assembly
W eight (Dry) kg/lb22.0/48.5 29.0/63.9
Lubrication
Specified gear oil (APL grade) GL5 GL5 (STD), GL5LSD (LSD)
Oil capacity liter (US/UK gal) 1.6 (0.42/0.35) 2.4 (0.63/0.53)


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ISUZU KB P190 2007

REAR AXLE 4B-5
Differential
N⋅m (kgf ⋅m/lb ⋅ft)

RTW 74BMF000101


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ISUZU KB P190 2007

REAR AXLE 4B-7
REAR AXLE ASSEMBLY
General Description
A03R300001

The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the cente
r
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The φ220 mm (8.6 in) or φ194mm (7.6 in) ring gea
r
rear axle uses a conventional ring and pinion gear set
to transmit the driving force of the engine to the rea
r
wheels. This gear set transfers this driving force at a
90 degree angle from the propeller shaft to the drive
shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered rolle
r
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with
12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings, which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing.

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ISUZU KB P190 2007

REAR AXLE 4B-9
REAR AXLE
1. Refer to Section 3E “W HEELS and TIRES” for
road wheel Disassembly procedure.
2. Refer to Section 5 “BRAKE” for rear brake removal procedure.





RTW 54BLF000401
Legend
1. Brake Drum
2. Bolt and Nut
3. Axle Shaft Assembly with Brake
4. Shim
5. Snap Ring
6. Axle Shaft
7. Retainer (with ABS)
Retainer (without ABS)
8. Double Taper Roller Bearing

9. Oil Seal
10. Bearing Holder
11. Rear Brake
12. Bolt and Nut
13. Differential Assembly
14. Rear Axle Case Assembly
15. W heel Pin
16. Axle Case Oil Seal
17. Front

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ISUZU KB P190 2007

4B-10 REAR AXLE
Disassembly
• Raise vehicle to the working level.
• Support the axle assembly with the proper jack
and chassis stands.
• Remove wheel and tire.
• Drain differential oil.
• Remove propeller shaft. (Refer to the section
“Rear Propeller Shaft”.)

1. Remove brake drum.
2. Remove ABS sensor. (Refer to the section “ABS”.)
3. Remove brake pipe from wheel cylinder.

420R300003



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ISUZU KB P190 2007

REAR AXLE 4B-13
17. Remove double taper roller bearing, oil seal,
bearing holder, and back plate from axle shaft b
y
means of a press.
• Discard used oil seal, double taper rolle
r
bearing, snap ring, retainer.




RTW 54BMH000201
Legend
1. Bench Press Fitting
2. Axle Shaft


18. Oil seal is removed from bearing holder.

19. Bearing outer race is removed from bearing
holder.
• W hen it cannot remove by hand, bearing
outer race is removed using installer 5-8840-
2119-0 and grip 5-8840-0007-0.




RTW 54BSH000701
20. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
• φ 194mm differential assembly has three kinds
of bolts.
Note the installation holes.
21. Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
22. Remove axle case oil seal.
• Discard used oil seal.



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ISUZU KB P190 2007

REAR AXLE 4B-15
Reassembly
1. Using the oil seal installer 5-8840-2202-0 and
grip 5-8840-0007-0, install new axle case oil seal.




RTW 54BSH000301

Note :
Confirm that the dimension : A should be 34.5 –
36.1 mm (1.36 – 1.42 in)







A03R300004

2. Install new oil seal in bearing holder, using the oil seal installer 5-8840-2404-0.






RTW 54BSH000501
Legend
1. Oil Seal
2. Bearing Holder


3. Drive wheel pin into axle shaft flange, using a hammer.
4. Differential assembly a. Clean the mating surface of axle case and differential carrier.
b.
Apply Three Bond 1215 (TB1215) or
equivalent on the surface of differential
assembly as flowing illustration.


RTW 74BSH000301
Legend
a. 3 mm (0.12 in)

c. Tighten bolts and nuts to the specified torque.


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ISUZU KB P190 2007