2007 ISUZU KB P190 transfer case

TRANSFER CASE 7D-17
LHD











RTW 77DMF000101
Legend

(1) Transfer Control Unit

(2) Nut


Removal
1. Disconnect the battery ground cable.
2. Disconnect the harness connector from the Transfe
r
control unit.
3. Remove the Transfer control unit.
Installation

1. Install the Transfer control unit.
Transfer control unit torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
2. Connect the harness connector to the Transfe
r
control unit.
3. Connect the battery ground cable.



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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-19
• Breather hose (Between the transfer case and the
transfer actuator assembly)
• Transfer actuator assembly
• Switch bracket
• 2-4 switch assembly (Gray harness cover)
• Neutral switch assembly (Black harness cover)
• Detent plugs, detent springs, and detent balls (2
parts each)
4. Use a flange holder (5-8840-0133-0) to remove the
end nut from the front companion flange.



RTW 77DSH000201

5. Remove the bolts attaching the rear cover to the
transfer case.

6. Strike the area around the front output shaft head and
the rear cover bolt holes with a plastic hammer to
remove the rear cover.

220R300022


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ISUZU KB P190 2007

7D-20 TRANSFER CASE
7. Remove the parts listed below from the rear cover.
• H-L sleeve
• H-L shift assembly
• 2-4 sleeve, synchronizer key, and front
synchronizer spring (do not remove the rear
spring)
• 2-4 shift assembly
• Shift drum and shift shaft
• Sun gear needle bearing

260R300001












8. Remove the oil pump strainer fixing bolts from the
rear cover.
9. Compress the retaining ring at the rear of the chain.
Strike the rear end of the main shaft with a plastic
hammer to remove the main shaft, transfer chain, and
front output shaft assembly from the rear cover. Be
careful not to damage the oil pump strainer.

226R30001

Legend

(1) Sun Gear Needle Bearing
(2) H-L Sleeve
(3) 2-4sleeve, synchronizer key, and front synchronizer spring
(4) 2-4 Shift ASM
(5) Shift Shaft
(6) H-L Shift ASM
(7) Shift Drum

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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

7D-22 TRANSFER CASE
15. Remove the snap ring from the main shaft.
16. Use a press to remove the 2-4 hub from the main
shaft.





17. Spread the edges of the retaining ring (1) while lightl
y
tapping on the sun gear input shaft end. Remove the
carrier and gear assembly from the transfer case.

226R300020

18. Remove the dog teeth snap ring from the carrier and
gear assembly.
19. Remove the planetary dog teeth and the sun gear
input shaft together with the thrust needle bearing.

2260R300021










20. Remove the carrier snap ring.
21. Use a press to remove the ball bearings.





22. Use a sliding hammer (5-8840-0084-0) and a needle
bearing replacer (5-8840-0027-0) to remove the
needle bearing from the center of the carrier and gea
r
assembly.
Legend

(1) Outer Retaining Ring
(2) Carrier and Gear ASM
(3) Thrust needle Bearing
(4) Sungear Input Shaft
(5) Planetary DogTeeth
(6) Dog Teeth Snap Ring

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ISUZU KB P190 2007

TRANSFER CASE 7D-23


23. Remove the retaining ring (spiral type) together with
the internal gear and the damper ring.

226R300004






24. Remove the snap ring.
25. Use a press to remove the front output shaft ball
bearings.
26. Remove the oil pump wire snap ring from the rear
cover.

27. Use a sliding hammer (5-8840-0084-0) and a needle
bearing replacer (5-8840-2788-0) to remove the
needle bearing from the front output shaft.


P1010023
Legend
(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring

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ISUZU KB P190 2007

7D-24 TRANSFER CASE
Internal Component Disassembly and Reassembly

226R300017















H-L Shift Disassembly
1. Remove the guide roller.
2. Use a vise to compress the H-L shift spring (inside the
assembly)





3. Remove the outer snap ring.
4. Remove the shift block assembly from the shift rod.





5. Use a socket and a vise to compress the shift block
spring (inside the assembly)
6. Remove the inner retaining ring.
7. Remove the collar (rear)
8. Remove the shift block spring.
9. Remove the collar (front)
10. Remove the shift block assembly
11. Remove the spring pin.
12. Remove the shift arm.

Legend

(1) Shift Arm
(2) Shift Block Assembly
(3) Inner Retaining Ring
(4) Collar (Front)
(5) Shift Block Spring
(6) Collar (Rear)
(7) Shift Rod
(8) Outer Snap Ring
(9) Guide Roller
(10) Spring Pin

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ISUZU KB P190 2007