2007 ISUZU KB P190 differential

REAR AXLE 4B-19
17. Install brake pipe and ABS sensor and tighten it
to the specified torque.
Torque : ABS Sensor 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
Brake Pipe 16 N ⋅m (1.6 kgf ⋅m/12 lb ⋅ft)
420R30003

18. Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19. Install brake drum.
• Install propeller shaft. (Refer to Section “Rea
r
Propeller Shaft”.)
• Refill differential oil.
• Install wheel and tire.
• Lower vehicle.




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ISUZU KB P190 2007

4B-20 REAR AXLE
DIFFERENTIAL ASSEMBLY
Disassemble View
Legend
1. Bolt
2. Bearing Cap
3. Differential Cage Assembly
4. Side Bearing Outer Race
5. Side Bearing
6. Adjust Shim
7. Flange Nut
8. Flange Assembly
9. Drive Pinion Shaft Assembly

415RY00005

10. Collapsible Spacer
11. Inner Bearing
12. Adjust Shim
13. Oil Seal
14. Outer Bearing
15. Inner Bearing Outer Race
16. Outer Bearing Outer Race
17. Differential Carrier




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ISUZU KB P190 2007

REAR AXLE 4B-21
Disassembly
1. Using holding fixture 5-8840-0275-0 and holding
fixture base 5-8840-0003-0, fix the differential
assembly to the bench.
425L100007

2.
Apply a setting mark to the side bearing cap and
the differential carrier then remove bearing cap.

425RS009

3. Remove differential cage assembly.
4. Remove side bearing outer race. After removal,
keep the right and left hand side bearing
assemblies separate to maintain inner and oute
r
race combinations.
5. Remove side bearing by using remover 5-8840-
0013-0, 5-8840-0014-0, adapter 5-8840-2196-0
(for φ220mm) and 9-8521-1743-0 (for φ194mm).
φ
φφ
φ
220mm



RTW 54BSH000101
φ
φφ
φ
194mm





RTW 54BSH000201

6. Note the thickness and position of the shims then
remove adjust shim.
7. Remove the flange nut by using pinion flange holder 5-8840-0133-0 after raising up its staked
parts completely.

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ISUZU KB P190 2007

REAR AXLE 4B-29
Starting torque :
φ220mm : 0.7-1.3 N ⋅m
(0.07-0.13 kgf ⋅m/6-11 lb ⋅in)
φ194mm : 0.7-1.1 N ⋅m
(0.07-0.11 kgf ⋅m/6-10 lb ⋅in)
Note :
• Do not overtighten or loosen and then
retighten the nut.
• Pinion nut torque will be in the range of 245-
294 N ⋅
⋅⋅
⋅
m (25-30 kgf ⋅
⋅⋅
⋅
m/181-217 lb ⋅
⋅⋅
⋅
ft) ( φ
φφ
φ
220mm)
and 177-275 N ⋅
⋅⋅
⋅
m (18-28 kgf ⋅
⋅⋅
⋅
m/130-203 lb ⋅
⋅⋅
⋅
ft)
( φ
φφ
φ
194mm).
425RW 018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.



RTW 54BSH000901

11. Adjust ring gear backlash. a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010

b. Insert the differential cage assembly with bearing outer races into the side bearing bores
of the carrier.


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ISUZU KB P190 2007

REAR AXLE 4B-31
φ
φφ
φ
194mm




RTW 54BSH000201
12. Install the side bearings together with the
selected shims by using installer 5-8840-2162-0
( φ 220mm) and 9-8522-1164-0 ( φ194mm), drive
handle 5-8840-0007-0 and pilot 9-8521-1743-0
( φ 194mm).

φ
φφ
φ
220mm
425L100010


φ
φφ
φ
194mm



425R300004

13. Install side bearing outer race.
14. Install differential cage assembly.
15.
Align the setting marks (1) applied at disassembly
then install the bearing cap.




425RS035



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ISUZU KB P190 2007

4B-34 REAR AXLE
Differential Cage Assembly
Disassembled View

425R300005
Legend
1. Bolt
2. Ring Gear
3. Lock Pin
4. Cross Pin

5. Pinion Gear
6. Side Gear
7. Thrust W asher (for Side Gear)
8. Differential Cage



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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-36 REAR AXLE
425R300010

Play in splines between the side gear and axle shafts. mm(in)
Standard Limit
φ220mm 0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)
φ
194mm 0.08 - 0.36
(0.003 - 0.014) 0.5 (0.02)
425L100014

Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of
thread to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as illustrated.
Torque : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)



425RW 033


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ISUZU KB P190 2007