Page 577 of 6020
FRONT WHEEL DRIVE 4C1-73
ILLUSTRATION PART NO. PART NAME
9-8522-
1164-0
(J-24244) Side bearing installer
5-8840-2852-0
Outer bearing installer
(for 2W D)
5-8522-0054-0
(J-290 15) Inner bearing installer
(for 4W D)
5-8840-2853-0
Hub oil seal installer
(for 2W D)
5-8840-2
117-0
(J-36827) Hub nut wrench
5-8840-2
119-0
(J-36829) Inner bearing installer (for 4W D)
5-8840-2854-0
Oil seal installer (for 4W D)
5-8840-2789-0
ABS sensor rotor installer
9-8522-
1270-0 Inner bearing installer (for 2W D)
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ISUZU KB P190 2007
Page 578 of 6020

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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Page 579 of 6020

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.
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Page 580 of 6020
4C2-2 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2W D) and 4 wheel drive (4W D) electrically b
y
driver's pressing the 4W D switch (push button type) on
instrument panel.
This system controls below operations.
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft b
y
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4W D out signal to other Electronic Hydraulic Control Unit.
System Diagrams
RUW 34BLF000201
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ISUZU KB P190 2007
Page 581 of 6020
SHIFT ON THE FLY SYSTEM 4C2-3
SHIFT ON THE FLY ELECTRICAL EQUIPMENT
Axle Shaft Connection and Disconnection
RUW 34BMF000101
Actuator Assembly
412RY00004
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ISUZU KB P190 2007
Page 582 of 6020
4C2-4 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM AND ASSOCIATION PARTS
RTW 440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.
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Page 583 of 6020
SHIFT ON THE FLY SYSTEM 4C2-5
Disassembly
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear
412RW 017
10. Snap Ring
Remove snap ring from front axle case by using a snap ring pliers.
11.Inner Shaft
Take out inner shaft from front axle case.
412RW 016
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring pliers.
412RW 015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and press.
Remover : 5-8840-2197-0
NOTE:
Be careful not to damage the shaft.
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Page 584 of 6020
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