2007 ISUZU KB P190 boot

FRONT SUSPENSION 3C-41
4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.


RTW 340SH000401
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and number of shims.
11. Remove caster shims and note the positions and number of shims.
12. Remove upper control arm assembly.
13. Remove upper control arm nut.
14. Remove plate.

15. Remove bushing by using remover 5-8840-0256-0.


RTW 340SH000501




RTW 340SH000601
16. Remove fulcrum pin.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
• Upper control arm
• Bushing
• Fulcrum pin


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ISUZU KB P190 2007

FRONT SUSPENSION 3C-49
CAUTION: Be careful not to damage the ball joint
boot.



RTW 340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.






450RS023

• After moving the ball joint 4 or 5 times, attach nut,
then measure the preload.
Starting torque: 1.3-3.2 N ⋅
⋅⋅
⋅
m (0.13-0.33 kgf ⋅
⋅⋅
⋅
m/0.9-
2.4 lb ⋅
⋅⋅
⋅
ft)








450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut, and then tighten them to the specified torque.
Torque: 57 N ⋅
⋅⋅
⋅
m (5.8 kgf ⋅
⋅⋅
⋅
m/42 lb ⋅
⋅⋅
⋅
ft)
3. Install nut and cotter pin, and then tighten the nut to the specified torque with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-51
CAUTION: Be careful not to damage the ball joint
boot.





901RW 271
7. Remove lower ball joint nut.
8. Remove lower ball joint bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with a new one.





450RS026
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N ⋅
⋅⋅
⋅
m (0.25-0.65 kgf ⋅
⋅⋅
⋅
m/1.8-
4.7 lb ⋅
⋅⋅
⋅
ft)







450RS024
• If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install lower ball joint bolt.
3. Install lower ball joint nut and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅
⋅⋅
⋅
ft)
4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-15


Disassembly
NOTE :
For the left side, follow the same steps as right side.

1. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the DOJ side).
CAUTION :
Take care not to damage the bellows during band removal.
2. Remove band (1).







3. Pry off circlip (1) with a screwdriver or equivalent.


4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or equivalent.



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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

BRAKES 5C-33
FRONT DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION



RTW 55CMF000501

Removal Steps
1. Brake flexible hose
2. Lock bolt
3. Caliper assembly
4. Pad assembly with shim
5. Clip; pad
6. Slide pin
7. Boot
8. Support bracket
9. Front hub and disc assembly

Installation Steps
9. Front hub and disc assembly
8. Support bracket
7. Boot
6. Slide pin
5. Clip; pad
4. Pad assembly with shim
3. Caliper assembly
2. Lock bolt
1. Brake flexible hose



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ISUZU KB P190 2007

BRAKES 5C-35


9. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C “FRONT
W HEEL DRIVE”.



Important Operations - Installation
9. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C “FRONT W HEEL
DRIVE”.




RUW 55CSH000101







8. Support Bracket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
206 - 245 (21.0 – 25.0 / 152 - 181)
Set up the clip and pad before installation of the support
bracket.
7. Boot
6. Slide Pin • Be sure to install the boots to the slide pin and the
support bracket securely.
•
Apply rubber grease to the sliding surface of the slide
pin before installation of the slide pin. (Don’t use mineral
type grease.)



















1) Assemble a slide pin boot to a slide pin.
2) Use 0.6g to apply grease to the slide pin entirely as shown bellow.
3) Insert the slide pin to the housing and make sure the boot is also inserted to the housing tightly.


5. Clip; Pad
Install new parts if necessary.




RUW 55CSH000201
2. Lock Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)


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ISUZU KB P190 2007

BRAKES 5C-41












Thickness of Disc Pad
Thickness (t) mm (in)

Standard Limit
10.0 (0.394) 1.8 (0.071)

Replace the front disc pad whenever the pad wear indicato
r
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.

All four brake pads should be replaced together.

302R300019


Seal and Boot
The dust seal, dust boot and ring seal should be replaced each
time the caliper is overhauled.
Discard these used rubber parts.


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ISUZU KB P190 2007