2007 ISUZU KB P190 transfer case

TRANSFER CASE 7D-25
H-L shift reassembly
1. Install the shift arm to the shift rod.
2. Install the spring pin. The top of the pin must be flush
with the surrounding surface (no projection).
3. Install the front collar, the spring, and the rear collar to
the shift block in that order.
4. Use a socket and a vise to compress the shift block
spring.
5. Install the inner retaining ring. Be sure that the arm
aperture width is within the specified limit.

226R300014






6. Install the shift lock assembly to the shift rod.
7. Use a socket and a vise to compress the H-L shift
spring.
8. Install the outer snap ring.
9. Install the guide roller.

2-4 shift ASM

226R300016











2-4 shift disassembly
1. Remove the guide roller.
2. Compress the spring and remove the snap ring.
3. Remove the shift arm.
4. Remove the spring.
5. Remove the spring pin.
6. Remove the shift block assembly.
7. Remove the shift rod.

Legend

(1) 25.62 °
(2) 14.1mm Legend
(1) Shift Rod
(2) Shift Arm
(3) Spring
(4) Shift Block Assembly
(5) Spring Pin
(6) Guide Roller
(7) Snap Ring

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ISUZU KB P190 2007

7D-26 TRANSFER CASE
2-4 shift reassembly
1. Install the shift block assembly to the shift rod.
2. Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.

226R300015
3. Install the spring.
4. Install the shift arm.
5. Compress the spring and install the snap ring.
6. Install the guide roller.

Oil pump disassembly
1. Remove the clamps securing the screen.
2. Remove the screen.
3. Remove the clamps securing the hose.
4. Remove the hose.
NOTE: To maintain and protect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Oil pump reassembly

1. Tighten the clamps to secure the hose.
2. Tighten the clamps to secure the screen.
NOTE: Be careful in the direction of clamps.

RTW 37DSH000101
Legend
(1) Oil Pump Assembly
(2) Clamp
(3) Hose
(4) Screen Assembly



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ISUZU KB P190 2007

TRANSFER CASE 7D-27
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. W ash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign material
are removed from the surfaces of every part. Appl
y
compressed air to each oil feed port and channel in
each case half to remove any obstructions or cleaning
solvent residue.

Inspection and Repair (Transfer Case
Assembly)
W hen wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or replaced. W ash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or
residual detergent.

Chain
• Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
• If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket
• Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
• If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear
• Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
• Remove minor flaws or scratches with oil stone. I
f
excessive wear or damage is observed, replace the
part.

2-4 and Neutral Switch

• Check the continuity of 2-4 and Neutral switch.
If defects are observed, replace the 4H and 4L switch.




221R300001
261R300003
Switch
Stroke 2-4 Switch
Signal Neutral Switch

Signal
Terminal
1 to 2 Terminal
1 to2
1 Open Close
2 Close Open



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ISUZU KB P190 2007

7D-28 TRANSFER CASE
Oil Pump
• Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play
• Set a dial indicator to the clutch hub to be measured.
• Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
• If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard: 0-0.1 mm (0-0.004 in)
Limit: 0.2 mm (0.008 in)

226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. W ash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.

Ball Bearing Play

1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit: 0.2 mm (0.008 in)

226R3043

Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
• Teeth for wear, scuffs, nicks, burrs or breaks.
• Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
• If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.


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ISUZU KB P190 2007

TRANSFER CASE 7D-29
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard: 2.46-2.74 mm (0.097-0.108 in)
Limit: 3.0 mm (0.118 in)
226RS037

2WD-4WD Synchronizer (3-Cone)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2W D-4W D synchronizer assembly must be replaced.
Block ring and dog teeth clearance
Standard: 1.5 mm (0.059 in)
Limit: 0.8 mm (0.031 in)

226R300019

Clutch Hub and Insert Clearance

1. Clutch Hub and Insert Clearance
2. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
3. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard: 0.01-0.19 mm (0.0004-0.0075 in)
Limit: 0.3 mm (0.012 in)

226RS038

Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.


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ISUZU KB P190 2007

7D-30 TRANSFER CASE
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard: 23.4 mm (0.92 in)
Limit: 22.8 mm (0.90 in)

220RW 035

Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent ball
Compressed height: 18.7 mm (0.736 in)
Standard: 68.6-88.2 N (7.0-9.0 kg/ 15.4-19.8 lb)

220RS013

Shift Arm

1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.

Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
H-L Shift arm thickness
Standard: 7.6-7.85 mm (0.299-0.309 in)
Limit: 7.0 mm (0.276 in)
2-4 Shift arm thickness
Standard: 9.6-9.85 mm (0.378-0.388 in)
Limit: 9.0 mm (0.354 in)


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ISUZU KB P190 2007

TRANSFER CASE 7D-31
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is reassembled.
1. Use an oil seal installer (5-8840-2785-0) to press the
new input shaft and/or front output shaft oil seals into
place (If replacement is required).






RTW 77DSH000301
2. Use a press to install the ball bearings to the front
output shaft. Be sure that the bearings are full
y
inserted and then install the snap ring.
3. Install the damper ring and the internal gear to the
transfer case. Be sure that the damper ring is
between the internal gear and the case.

226R300004






Note the direction of the dumper ring installation as
figure.

226R300025
Legend

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

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ISUZU KB P190 2007

7D-32 TRANSFER CASE
4. Use a press and an installer (5-8840-2784-0) to hold
the internal gear against the damper ring. Install the
retaining ring (spiral type).





5. Use a press and an installer (5-8840-2782-0) to force
the needle bearing fully into the carrier and gear
assembly.





6. Use a press and an appropriate special tool to force
the ball bearings fully into the carrier and gear
assembly.





7. Install the carrier snap ring.
8. Install the thrust needle bearing, the sun gear input
shaft, the needle bearing, the planetary dog teeth, and
the dog teeth snap ring to the carrier and gea
r
assembly in that order.
9. Install the outer retaining ring to the transfer case
10. Use a pair of snap ring pliers to install the carrier and gear assembly.
NOTE: Be sure that the outer retaining ring fits snugly in
its groove.


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ISUZU KB P190 2007