2007 ISUZU KB P190 Speedometer

7B1-32 Manual Transmission (MUX)
Snap Ring Availability51. Install the new snap ring to the output shaft. • Never reinstall the used snap ring.
52. Install the speedometer drive gear. (4x2 model)
53. Install the gear set clip. (4x2 model)
54. Install the end cover assembly.
• The gasket must be assembled. (4x2 model)
• Apply recommended liquid gasket (LOCTITE FMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below. (4x4
model)
• Tighten the end cover bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
55. Install the speedometer driven gear and plate. (4x2 model)
56. Install the control rod detent assembly.
• Tighten the three detent assemblies to thespecified torque.
Torque: 30 N ⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
57. Install the new 5th detent assembly and new reverse detent assembly.
• Never reinstall the used detent assembly.
• Tighten the three detent assemblies to the specified torque. Torque: 30 N
⋅m (3.1 kgf ⋅m/22 lb ⋅ft)
58. Install the two harness brackets.
Torque: 8N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
59. Install the reverse switch (Connector color Brown), 1st switch (Connector color Gray) and neutral
switch (Connector color Brown) with gasket.
• Tighten the three switches to the specified torque.
Torque: 39 N ⋅m (4.0 kgf ⋅m/29 lb ⋅ft)
60. Install the control unit block by performing the following steps.
a. Push the control unit block ahead.
b. Install the control unit block.
c. Install the new taper bolt.
• Never reinstall the used taper bolt.
• Tighten the taper bolt to the specified torque.
Torque: 47 N ⋅m (4.8 kgf ⋅m/35 lb ⋅ft)
Important: • Must be checked no flaw to taper bolt.
• Must be checked no jam of foreign body before assembled.
• Must be checked same position upper surface of the taper bolt and the control unit block after
assembled.
61. Install the two dowels and quadrant box. • Apply recommended liquid gasket (LOCTITEFMD-127 or equivalent) with the width of 3 to 5
mm to the area marked in the figure below.
• Tighten the quadrant box bolts to the specified torque.
Torque: 23 N ⋅m (2.3 kgf ⋅m/17 lb ⋅ft)
62. Remove the tape from the spline portion of the input shaft.
Thickness
Identification color
2.1 mm(0.083 in) White
2.2 mm(0.087 in) Blue
2.3 mm(0.091 in) Green
2.4 mm(0.094 in) Yellow
2.5 mm(0.098 in) Orange
2.6 mm(0.102 in) Black
RTW77BSH005601
RTW77BSH005701

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ISUZU KB P190 2007

7D-18 TRANSFER CASE
Transfer Disassembly



RTW 67DLF000101
Legend

(1) Transfer Case Speedometer Bushing, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut
(8)
(M/T: MUA, MUX, A/T: JR405E, AW 30-40LE)
(3) Stoneguard (9) Speed sensor (M/T: AR-5, A/T: 4L60-E)

(4) Detent Plug, Spring and Detent Ball (10) Transfer Actuator (Diesel Engine)
(5) 2-4 Switch ASM (11) Transfer Actuator (Gasoline Engine)
(6) Switch Bracket (12) Breather Hose
(7) Neutral Switch ASM (13) Heat Protector (Gasoline Engine)

Removal

1. Remove the stoneguard.
2. Remove the drain plug from the transfer case to drain
the oil.
3. Remove the parts listed below.
• Speedometer bushing, plate, and speedomete
r
driven gear (M/T: MUA, MUX, A/T: JR405E,
AW 30-40LE)
• Speed sensor (M/T: AR-5, A/T: 4L60-E)

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ISUZU KB P190 2007

TRANSFER CASE 7D-21
10. Remove the transfer chain and the front output shaft
from the main shaft.
11. Remove the main shaft snap ring.
12. Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13. Remove the sprocket snap ring.
14. Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.


RTW 37DMF000101
Legend
(8) Thrust W asher
(1) Rear synchronizer spring
(9) Sprocket Snap Ring
(2) Block Ring
(10) Oil Pump ASM
(3) Outside Ring
(11) Oil Pump Retaining Ring
(4) Inside Ring
(12) Retaining Ring
(5) Drive Sprocket
(13) Ball Bearing
(6) Transfer Chain (14) Speedometer Drive Gear
(7) Front Output shaft (15) Main Shaft Snap Ring


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ISUZU KB P190 2007

TRANSFER CASE 7D-37
226R300005



30. Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31. Use a press and an installer (9-8522-1268-0) to install
the rear output shaft ball bearings. Do not drive the
ball bearings into place with a hammer.





32. Install the rear output shaft retaining ring.
33. Place the oil pump in its specified position.
34. Secure the oil pump strainer to the rear cover and
tighten the bolts to the specified torque.
Oil pump and rear cover bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)


226R300010










35.
Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
Legend

(1) Oil Pump Assembly
(2) W ire Snap Ring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend
(1) W ire Snap Ring

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ISUZU KB P190 2007

TRANSFER CASE 7D-39
43. Use an installer (5-8840-2787-0) to install the main
shaft end snap ring to the rear output shaft (from the
back end of the shaft). Be absolutely sure that the
snap ring is seated in the groove.

226R300022

44. Use an installer (5-8840-2786-0) to install the rear
output oil seal to the rear case.


RTW 77DSH000401


220R300021
45.
Install the detent balls, the detent springs, and the
detent plugs (2 parts each) to the transfer case.
Tighten the plugs to the specified torque.
Detent plug torque: 19 N ·m (1.9 kgf ·m/14 lb ·ft)
46. Install the neutral switch (black harness cover) to the
transfer case and tighten the bolts to the specified
torque.
Neutral switch bolt torque:
39 N ·m (4.0 kgf ·m/29 lb ·ft)
47. Install the 2-4 switch (gray harness cover) to the
transfer case and tighten the bolts to the specified
torque.
2-4 switch bolt torque: 39 N ·m (4.0 kgf ·m/29 lb ·ft)
48. Install the switch bracket to the transfer case and
tighten the bolts to the specified torque.
Switch bracket bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)
49. Install the transfer actuator assembly to the transfe
r
case and tighten the bolts to the specified torque. The
actuator must be installed in the same direction as the
shaft.
Transfer actuator assembly bolt torque:
22 N ·m (2.2 kgf ·m/16 lb ·ft)
50. Install the breather hose between the transfe
r
actuator and the transfer case.
51. Install the speedometer driven gear, the speedomete
r
bushing, and the speedometer stay to the transfe
r
case. Tighten the bolts to the specified torque. (M/T:
MUA, MUX, A/T: JR405E, AW 30-40LE)
Speedometer bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)

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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-61
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once.
Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3.
Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace this
chart from the beginning.
3 Shift to 2H.
Can be shifted to 2H and then to
4H? Go to step 4.
Refer to the paragraph about
shifting from 2H to 4H.
In particular, check if not at the
Check4W D condition, return to
this chart and trace it from the
beginning.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Shift back to 4H and go to step 5.
5
Start the engine and use the
vehicle.
Does the speedometer run at
this time? Go to step 6.
Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble detected? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7
Run the vehicle for several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met? Failed controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1 second
or maximum 3 minutes,
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)


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ISUZU KB P190 2007

7D1-62 TRANSFER CONTROL SYSTEM
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once.
Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3.
Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace this
chart from the beginning.
3 Can be shifted to 2H and then to
4L? Go to step 4.
(Impossible usually.)
Failed controller In case of Check 4W D, shifting to
2H is possible.
Returning to 4L is impossible.
Refer to the paragraph about
Check4W D.
4 Set to N position in case of AT
and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Press the operation switch of 4L
and go to step 5.
5 Start the engine and use the
vehicle.
Does the speedometer run at
this time? Go to step 6.
Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the
transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble detected? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7
Run the vehicle for several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met? Failed transfer controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1 second
or maximum 3 minutes,
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)



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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-63
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz.
Check the function between H and L according to the chart for 4L to 4H instead of check
for the requirements of neutral.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
2 Turn ON the ignition switch and
check the valve. Do not start the
engine.
Has the valve check for 2
seconds been completed
normally? Go to step 3.
Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H (7D1-
37).
After taking the remedy, trace this
chart from the beginning.
3 Can be shifted to 2H and then to 4L? Go to step 4.
(Impossible usually.)
Failed controller Refer to the paragraph about
shifting from 2H to 4H.
In particular, check if not at the
Check4W D condition, return to
this chart and trace it from the
beginning.
In case of Check4W D, shifting to
2H is possible.
Returning to 4H is impossible.
Refer to the paragraph about
Check4W D.
4 Set to N position in case of AT and set to the neutral position in
case of MT and check if the lamp
blinks at 4Hz after operation. Failed T/M position switch and
harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
chart from the beginning. Shift back to 4H and go to step 5.
5 Start the engine and use the
vehicle.
Does the speedometer run at this
time? Go to step 6.
Failure of speed sensor or
disconnection or short of harness
(for the meter).
After repairing, trace this chart
from the beginning.
6 Check the harness between the transfer controller and speed
sensor.
(Check the engine rotation
detection harness at the same
time.)
Is any trouble noticed? Failed harness between the
transfer controller and speed
sensor.
After repairing, trace this chart
from the beginning.
(Repair the engine rotation
detection unit, if required.) Go to step 7.
7 Run the vehicle for several
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were met? Failed controller.
Replace the controller and trace
this chart from the beginning. You did not wait for enough time.
Optimum waiting time is 1 second
or maximum 3 minutes,
depending on the previous
conditions.
Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)
For shifting to neutral, 2H and 4L switches should be pressed at the same time for 10 seconds.
For shifting from neutral to other position, 2H, 4H or 4L switch should be pressed for 10 seconds.
W hen shifting from neutral to other position, the lamp blinking at 2Hz indicates active condition.
W hen the lamp keeps blinking at 2Hz, follow the step for the case when the lamp keeps blinking at 2Hz when
shifting between positions.


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ISUZU KB P190 2007