2007 ISUZU KB P190 check oil

4C1-66 FRONT WHEEL DRIVE
4× 4 MODEL
1. OIL LEAK AT FRONT AXLE

Checkpoint Trouble Cause Countermeasure

Front axle housingRepair or replaceCracked
Replace the oil sealW orn or defective oil seal
NG
NG
OKOil seal



2. OIL LEAK AT PINION SHAFT

Oil sealReplace the oil sealW orn or defective
Correct the oil levelToo much gear oil
NG
NG
OKGear oil level
Pinion flangeTighten or replaceLoose or damaged
NG
OK



3. NOISES IN FRONT AXLE DRIVE SHAFT JOINT


Replace the drive shaft joints
and bellows

Broken or worn

NG
Drive shaft joints and bellows
(UJ and DOJ)




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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-67
4. NOISES IN FRONT AXLE
Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil
NG
Replace the wheel bearing
Replace the pinion shaft
bearing
Replace the ring gear pinion
gear or side gear
Replace the gear oil
W heel bearingWorn
Pinion shaft bearingWorn
W orn or chipped
W rong or poor grade gear oil
Ring gear, pinion gear or side
gear
Adjust the backlashDrive pinion to ring gear
backlashToo much or too little backlash
NG
NG
NG
NG
NG
OK
OK
OK
OK
Oil level
Tighten or replaceDifferential bearingLoose or worn
NG
OK



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ISUZU KB P190 2007

4C2-6 SHIFT ON THE FLY SYSTEM





412RS045
14.Needle Bearing
Remove needle bearing from inner shaft by using a special tool.
Remover : 5-8840-0027-0
Sliding hammer : 5-8840-0084-0
NOTE:
Be careful not to damage the shaft.
15.Oil Seal
Remove oil seal from front axle case.
NOTE:
Be careful not to damage the front axle case.

Inspection and Repair
Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.

Visual Check
• Check and see if the inner shaft has such
abnormalities as wear and damage.








412RW 014





412RS008
•
W hen inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormalit
y
in its gear part (a slide with sleeve), replace the shaft.


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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-7















412RS026
Inner Shaft Run-Out
W ith both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit) mm (in)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.






RTW 440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smooth less is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smooth less, replace the
needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or checking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.











412RW 011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smooth less is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.






412RW 022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

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ISUZU KB P190 2007

4C2-8 SHIFT ON THE FLY SYSTEM




RTW 440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, o
r
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as smooth less when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.





RTW 440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)




RTW 440SH000501




RTW 440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or othe
r
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.

State Port 3Port 4Port 1, 2
Conducting Function
A
+ −
−−
−
C
B −
−−
−
+ × D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

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SHIFT ON THE FLY SYSTEM 4C2-9



RTW 440SH000601









RTW 440SH000801
Dimension Check
Measure illustration sized A, B, and C
Limit mm (in)

A 64.3 (2.53)
B 6.7 (0.26)
C 6.7 (0.26)













RTW 440SH000701




Reassembly
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer 5-8840-2407-0
Grip 5-8840-0007-0

























412RS051



14. Needle Bearing
Force a new needle bearing into inner shaft by using a
special tool.
Installer : 5-8840-2408-0
Grip : 5-8840-0007-0

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ISUZU KB P190 2007

ANTI-LOCK BRAKE SYSTEM 5B-17



RUW 55BMF000101

Legend
(1) Bench Press Fitting
(2) Axle Shaft


(3) Sensor Rotor
Inspection and Repair
Make all necessary adjustments, repairs or part
replacement.
• Check damage or powdered iron sticking to the
sensor rotor.
• Check play in the sensor rotor.
• Check a broken tooth or indentation in the senso
r
rotor.
NOTE: If replacement is required, remove the
sensor rotor from the axle shaft assembly with
brake. (Refer to the section Rear Axle).
• Discard the used sensor rotor.
(Snap ring, Oil seal and Bearing)
Installation
1. Install the sensor rotor and assemble it into the
axle shaft assembly with back plate, using setting
tool 9-8522-1271-0. (Refer to the section Rea
r
Axle)

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ISUZU KB P190 2007

5C-24 BRAKES
RTW 35CSH000201
3) Rear wheel cylinder fluid pressure measurement
Step on the brake pedal until the fluid pressure of the front wheel cylinder gets to 9.8Mpa (100kg/cm
2), and
check the rear wheel cylinder fluid pressure. (Read the
value of the front wheel cylinder fluid pressure 2
seconds after the measurement. W hen measuring the
LSPV fluid pressure, keep the brake pedal pressed
down without stepping it down twice or releasing it.)
Rear W heel Cylinder Fluid Pressure MPa (kg/cm
2)
2W D 6.77 ±0.83 (69.0 ±8.5)
2W D (W ith High Ride
Suspension), 4W D 6.77
±0.83 (69.0 ±8.5)

RTW 35CSH000401
2. Oil Pressure Adjustment
1) LSPV spring length adjustment
Loosen the adjust nut of the LSPV spring joint, and adjust the length of the LSPV spring.
W hen the oil pressure is insufficient, turn the adjust nut clockwise to extend the span “A”. W hen the oil pressure
is too high, turn the adjust nut counterclockwise to
reduce the span “A”.


2) After adjustment, tighten the lock nut securely.
Lock Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
11-20 (1.1-2.0/8-14)


















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ISUZU KB P190 2007