2007 ISUZU KB P190 Workshop Repair Manual

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Page 4857 of 6020

ISUZU KB P190 2007 Workshop Repair Manual TRANSFER CASE 7D-27
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. W ash all parts tho

TRANSFER CASE 7D-27
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. W ash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign material
are removed from the surfaces of every part. Appl
y
compressed air to each oil feed port and channel in
each case half to remove any obstructions or cleaning
solvent residue.

Inspection and Repair (Transfer Case
Assembly)
W hen wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or replaced. W ash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or
residual detergent.

Chain
• Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
• If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket
• Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
• If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear
• Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
• Remove minor flaws or scratches with oil stone. I
f
excessive wear or damage is observed, replace the
part.

2-4 and Neutral Switch

• Check the continuity of 2-4 and Neutral switch.
If defects are observed, replace the 4H and 4L switch.

221R300001
261R300003
Switch
Stroke 2-4 Switch
Signal Neutral Switch

Signal
Terminal
1 to 2 Terminal
1 to2
1 Open Close
2 Close Open

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Page 4858 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7D-28 TRANSFER CASE
Oil Pump
• Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damage

Page 4859 of 6020

ISUZU KB P190 2007 Workshop Repair Manual TRANSFER CASE 7D-29
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limi

Page 4860 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7D-30 TRANSFER CASE
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring m

Page 4861 of 6020

ISUZU KB P190 2007 Workshop Repair Manual TRANSFER CASE 7D-31
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is r

Page 4862 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7D-32 TRANSFER CASE
4. Use a press and an installer (5-8840-2784-0) to hold
the internal gear against the damper ring. Install the
retaining ring (spiral type).

5. Use a press and

Page 4863 of 6020

ISUZU KB P190 2007 Workshop Repair Manual TRANSFER CASE 7D-33
226R300003

11. Use a press to install the 2-4 hub.

12. Install the hub snap ring.
13. Install the synchronizer key springs, the synchroniz

Page 4864 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 7D-34 TRANSFER CASE
14. Insert the H-L sleeve into the main shaft.

226R300023
Legend

(1) H-L Sleeve
(3) Synchronizer Key and Key Spring

(2) 2-4 Sleeve

15. Install the slee

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