2007 ISUZU KB P190 service

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

4B-2 REAR AXLE
Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE REFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the prope
r
location. When you replace a fastener, use ONLY
the exact part number for that application.
ISUZU/GM will call out those fasteners that require
a replacement after removal. ISUZU/GM will also
call out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints,
greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener torque
and the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.


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ISUZU KB P190 2007

4B-56 REAR AXLE

SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME
5-8840-2831-0

Bearing Remover
5-8840-0007-0
(J-8092)

Grip
5-8840-2119-0
(J-36829)

Installer
5-8840-0079-0
(J-6627-A)

W heel Pin Remover
5-8840-2202-0


Oil Seal Installer
5-8840-2404-0

Oil Seal Installer
9-8522-1271-0
(J-8609-01)

Support Stand
5-8840-0275-0
(J-37264)

Holding Fixture
5-8840-0003-0
(J-3289-20)

Holding Fixture Base

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ISUZU KB P190 2007

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4×2 Except High Ride Suspension Model) ..................................4C1- 38 Disassembly .................................................................................................................4C1 - 38
Inspection and Repair .................................................................................................4C1- 41
Reassembly ..................................................................................................................4C1 - 42
Front Hub and Disc
(4×4, 4×2 High Ride Suspension, 4×4 Rigid Hub, 4×4 Shift On the Fly Model) ..........4C1- 46 Disassembly .................................................................................................................4C1 - 46
Inspection and Repair .................................................................................................4C1- 48
Reassembly ..................................................................................................................4C1 - 49
Front Hub and Disc (4×4 Manual Locking Hub Model)..................................................4C1- 53 Disassembly .................................................................................................................4C1 - 53
Inspection and Repair .................................................................................................4C1- 56
Reassembly ..................................................................................................................4C1 -57
Troubleshooting ...............................................................................................................4 C1-63
Special Service Tool.........................................................................................................4C 1-71


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-71
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME
5-8840-2309-0 Ft axle mount bushing installer & remover
5-8840-2745-0 Pliers
5-8840-00
13-0
(J-22888) Side bearing remover
9-852
1-1 743-0
(J-8 107-2) Side bearing plug adapter
5-8840-0
133-0
(J-86 14-0 1) Pinion flange holder

9-852
1-5032-0 Final pinion spindle
5-8840-00
15-0
(J-229 12-0 1) Separator
9-8522-
1141-0
(J-24256) Outer bearing outer race installer
5-8840-0007-0
(J-8092) Grip

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ISUZU KB P190 2007

SH IF T O N T H E FL Y S Y STEM 4 C2
SECTION 4C2
SHIFT ON THE FLY SYSTEM
TABLE OF CONTENTS

Service Precaution ............................................. 4C2-1
Shift On The Fly System .................................... 4C2-2 Outline of Shift on The Fly System .................. 4C2-2
Shift On The Fly Electrical Equipment................ 4C2-3 Axle Shaft Connection and Disconnection ...... 4C2-3
Actuator Assembly .......................................... 4C2-3

Shift On The Fly System and Association
Parts .................................................................. 4C2-4 Disassembly .................................................... 4C2-5
Inspection and Repair ..................................... 4C2-6
Reassembly .................................................... 4C2-9
Torque Specifications...................................... 4C2-12
Special Service Tool ....................................... 4C2-13




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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-1

SERVICE PRECAUTION
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require
a replacement after removal. ISUZU/GM will also
call out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-13
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

5-8840-0007-0
（ J-8092 ） Grip

5-8840-2407-0
（ J-41693 ） Installer: Oil seal

5-8840-2408-0
（ J-41694 ） Installer: Bearing needle

5-8840-0027-0
（ J-26941 ） Remover: Bearing needle

5-8840-0084-0
（ J-2619-01 ） Hammer: Sliding

5-8840-2197-0
（ J-37452 ） Remover: Bearing inner shaft


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ISUZU KB P190 2007