2007 ISUZU KB P190 differential

FRONT WHEEL DRIVE 4C1-29
Major Components


RTW 54CLF000201

Reassembly Steps
1. Diff. carrier
▲ 2. Outer bearing outer race
▲ 3. Inner bearing outer race
▲ 4. Adjust shim
▲ 5. Inner bearing
▲ 6. Collapsible spacer
7. Pinion gear
8. Outer bearing
▲ 9. Oil seal
10. Dust cover


11. Flange
▲ 12. Flange nut
▲ 13. Adjust shim
▲ 14. Side bearing
15. Bearing outer race
16. Diff. cage assembly
▲ 17. Bearing cap
▲ 18. Bolt
19. Axle case
▲ 20. Differential assembly
21. Bolt



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-33
(7) Select the shim using the chart;

mm(in)
Pinion
marking
+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10 Dial indicator
reading (inches)
0.081 2.18 (0.0858)0.082 2.18 (0.0858) 2.20 (0.0866)0.083 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)0.084 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)0.085 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.086 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913)0.087 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921)0.088 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929)0.089 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937 )0.090 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953)0.091 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961)0.092 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969)0.093 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976)0.094 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992)0.095 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000)0.096 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.097 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.098 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.099 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.002 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.003 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.005 2.54 (0.1000) 2.56 (0.1008) 0.006 2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.








5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.



6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.








9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.


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ISUZU KB P190 2007

4C1-34 FRONT WHEEL DRIVE







12. Flange Nut and Washer

(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion flange holder.
Pinion flange holder : 5-8840-0133-0
Torque N ⋅m (kgf ⋅m/lb ⋅ft
)
177 - 275 (18 - 28/130 - 202)
Discard used flange nut and install new one.






(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is obtained.
Starting Torque N⋅m (kgf ⋅m/lb ⋅in
)
0.63 - 1.13 (0.06 – 0.12/5 - 10)


13. Adjust Shim
(1)
Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.

1 Installer : 9-8522-1164-0
2 Drive handle : 5-8840-0007-0
3 Pilot : 9-8521-1743-0




(2) Insert the differential cage assembly with bearing oute
r
races into the side bearing bores of the carrier.



(3) Using two sets of feeler gauges, insert a feeler stock o
f
sufficient thickness between each bearing outer race and
the carrier to remove all end plat. Make certain the feele
r
stock is pushed to the bottom of the bearing bores.
Mount the dial indicator on the carrier so that the indicato
r
stem is at right angles to a tooth on the ring gear.
Dial indicator : 5-8840-0126-0


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-37
















20. Differential Assembly
(1) Clean the faces of the front axle case and differential carrier.

Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2)
Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
26 (2.7/20)
(3) Install the axle shaft assemblies as instructed earlier in this section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just belo
w
the filler hole.
Lubricant capacity liter (US/UK gal)
1.4 (0.37/0.31)



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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

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

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing
• Place a new snap ring in inner shaft.
• Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft • Clean the housing contact surface of the front axle
case.
• Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.






412RW 017
10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear Apply differential gear oil to clutch oil.
8. Sleeve Apply differential gear oil to sleeve.






412RW 023


7. Housing
• Clean contact surface with the front axle and actuato
r
mounting surface.
•
Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
75 (7.6/55)

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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator • Clean the actuator contact surface with the housing.
•
Apply liquid gasket to the contact surface on the
actuator side.
• Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N⋅m (kgf ⋅m/lb ⋅in)
9 (0.9/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt • Install front axle drive shaft and mounting bracket.
• Tighten fitting bolts to specified tightening torque.
Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
116 (11.8/85)
1. Filler Plug • Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal) 0.12 (0.03/0.03)
• Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque N⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0/58)



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ISUZU KB P190 2007