2007 ISUZU KB P190 lock

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacture Remarks

RTV* Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
W ater Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket. Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262
Red 2. Apply LOCTITE to the bolts.


LOCTITE 270
Green

LOCTITE 271
Red
3. Tighten the bolts to the specified torque.
4. W ait at least on hour before continuing the installation procedure.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-11

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front W heel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in this section.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-13


NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kgf·m/73 lb·ft)
9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque.
Torque : 93 N·m (9.5kgf·m/69 lb·ft)
10. Install lower nuts of the stabilizer link, tighten it to the specified torque.
Torque : 50 N·m (5.1kgf·m/37 lb·ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake system.
16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque.
Torque : 226 N·m (23.0kgf·m/166 lb·ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Front Alignment section.
20. Tighten the bolts and nuts of the lower control arm to the specified torque.
Refer to Lower Control Arm in Suspension section.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-23
Minor Components



Disassembly Steps
1. Bolt
2. Ring gear
▲ 3. Lock pin
▲ 4. Cross pin


5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage



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ISUZU KB P190 2007

4C1-24 FRONT WHEEL DRIVE
Important Operations
3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.


4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-27
Reassembly
Minor Components



Reassembly Steps
1. Differential cage
2. Thrust washer
3. Side gear
▲ 4. Pinion gear


▲
5. Cross pin
▲ 6. Lock pin
▲ 7. Ring gear
▲ 8. Bolt




Important Operations
4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.


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ISUZU KB P190 2007

4C1-28 FRONT WHEEL DRIVE


5. Cross Pin
(1) Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage.



(2) Adjust the backlash between the side gear and the pinion
gear. mm(in)
Backlash 0.10 - 0.20 (0.004 - 0.008)
Thickness of thrust washers available
mm(in)
1.00, 1.05, 1.10 (0.039, 0.041, 0.043)



6. Lock Pin
After lock pin installation, stake the cage to prevent discharge
of the lock pin.


7. Ring Gear
W hen installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.






8. Bolt
Tighten the bolts in diagonal sequence as illustrated.
Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
108 (11.0/80)
Note :
Discard used bolts and install new ones.
Note that all bolts have a left hand thread.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-31








Tighten the nut to the specified torque.
N⋅m (kgf ⋅m/lb ⋅in)
New bearing 2.3 (0.23/20)
Used bearing 0.98 - 1.18
(0.10 – 0.12/9 – 10)
(2) Clean the side bearing bores. Install the dial indicator with the discs and Arbor. Install and tighten the bearing caps to
the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
98 (10.0/72)

1 Dial indicator : 5-8840-0126-0
2 Disc (2 pcs.) : 5-8840-2088-0
3 Arbor : 5-8840-0128-0
4 Gage plate : 5-8840-2087-0




(3) Set the dial indicator to “0”. Place it on the mounting post of
the gaging arbor with the contact button touching the
indicator pad. Force the dial indicator downward until the
needle has made a half turn clockwise. Tighten down the
dial indicator in this position.




(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.


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ISUZU KB P190 2007