ISUZU KB P190 2007 Workshop Repair Manual

REAR AXLE 4B-27
h. Select the shim using table below.
[ φ
φφ
φ
220 mm]
mm (in) Pinion
marking
+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10 Dial indicator
reading (inches)
0.073 1.94 (0.0764) 1.96 (0.0772)0.074 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780)0.075 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787)0.076 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803)0.077 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811)0.078 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819)0.079 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827)0.080 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843)0.081 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850)0.082 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858)0.083 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866)0.084 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882)0.085 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890)0.086 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.087 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913)0.088 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921)0.089 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929)0.090 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.091 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.092 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.093 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.094 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.095 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 0.096 2.34 (0.0921) 2.36 (0.0929) 0.097 2.36 (0.0929)
[ φ
φφ
φ
194 mm]
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) 0.000 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.


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ISUZU KB P190 2007

4B-28 REAR AXLE
4. Place the shim on the drive pinion, then install the
inner bearing onto the pinion by using installer 9-
8522-1165-0 and a press.
Note:
Do not apply pressure to the roller cage. Apply
NOTE: pressure only to the inner race.
425L100008

5. Install collapsible spacer. Discard the used collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal.
8. Use oil seal installer 5-8840-2165-0 ( φ220mm)
and 9-8522-1275-0 ( φ194mm) to install a new oil
seal that has grease on seal lip.

φ
φφ
φ
220mm
415RW 029

φ
φφ
φ
194mm


415RW 024

9. Install flange assembly.
10. Install flange nut. a. Apply lubricant to the pinion threads.
b. Using the pinion flange holder 5-8840-0133-0, tighten the nut only enough to remove the shaft
end play.
Note :
Discard used flange nut and install new one.
415RW 040
c. Adjust pinion bearing preload.
• Measure the bearing preload by using a torque
meter and note the scale reading required to
rotate the flange.
• Continue tightening flange nut until the
specified starting torque is obtained.



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ISUZU KB P190 2007

REAR AXLE 4B-29
Starting torque :
φ220mm : 0.7-1.3 N ⋅m
(0.07-0.13 kgf ⋅m/6-11 lb ⋅in)
φ194mm : 0.7-1.1 N ⋅m
(0.07-0.11 kgf ⋅m/6-10 lb ⋅in)
Note :
• Do not overtighten or loosen and then
retighten the nut.
• Pinion nut torque will be in the range of 245-
294 N ⋅
⋅⋅
⋅
m (25-30 kgf ⋅
⋅⋅
⋅
m/181-217 lb ⋅
⋅⋅
⋅
ft) ( φ
φφ
φ
220mm)
and 177-275 N ⋅
⋅⋅
⋅
m (18-28 kgf ⋅
⋅⋅
⋅
m/130-203 lb ⋅
⋅⋅
⋅
ft)
( φ
φφ
φ
194mm).
425RW 018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.



RTW 54BSH000901

11. Adjust ring gear backlash. a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010

b. Insert the differential cage assembly with bearing outer races into the side bearing bores
of the carrier.


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ISUZU KB P190 2007

4B-30 REAR AXLE

425RS030

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

425RW 049

d.
Adjust feeler gauge thickness from side to
side until ring gear backlash is in the specified
range.
Backlash :
φ220mm : 0.15-0.20 mm (0.006-0.008 in)
φ194mm : 0.13-0.18 mm (0.005-0.007 in)


425RS032

W ith zero end play and correct backlash established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use
new shims.
e. Remove side bearing by using remover 5- 8840-0013-0 and 5-8840-0014-0 and adapte
r
5-8840-2196-0 ( φ220mm) and 9-8521-1743-0
( φ 194mm).
φ
φφ
φ
220mm



RTW 54BSH000101


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ISUZU KB P190 2007

REAR AXLE 4B-31
φ
φφ
φ
194mm




RTW 54BSH000201
12. Install the side bearings together with the
selected shims by using installer 5-8840-2162-0
( φ 220mm) and 9-8522-1164-0 ( φ194mm), drive
handle 5-8840-0007-0 and pilot 9-8521-1743-0
( φ 194mm).

φ
φφ
φ
220mm
425L100010


φ
φφ
φ
194mm



425R300004

13. Install side bearing outer race.
14. Install differential cage assembly.
15.
Align the setting marks (1) applied at disassembly
then install the bearing cap.




425RS035



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ISUZU KB P190 2007

4B-32 REAR AXLE
16. Tighten the bolt to the specified torque.
Torque :
φ220mm : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 98 N ⋅m (10 kgf ⋅m/72 lb ⋅ft)


425RS036
• Measure the amount of run-out of the ring gear at
its rear face. It should be 0.05 mm (0.002 in) o
r
less
Gear Tooth Contact Pattern Check and Adjustment
1.
Apply a thin coat of Prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring gea
r
teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.





425RS038
Legend
1. Heel
2. Toe
3. Concave Side(Coast)
4. Convex Side(Drive)



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REAR AXLE 4B-33

425RS039



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ISUZU KB P190 2007

4B-34 REAR AXLE
Differential Cage Assembly
Disassembled View

425R300005
Legend
1. Bolt
2. Ring Gear
3. Lock Pin
4. Cross Pin

5. Pinion Gear
6. Side Gear
7. Thrust W asher (for Side Gear)
8. Differential Cage



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REAR AXLE 4B-35
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion gear on side gear before removal of cross pin.
Backlash : φ220mm : 0.13-0.18 mm (0.005-0.007 in)
φ194mm : 0.10-0.20 mm (0.004-0.008 in)
5. Remove the cross pin by using a brass drift punch and hammer.




425RS043

6. Take out pinion gear, side gear and thrust washer.

Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:
• Ring gear, pinion gear
• Bearing
• Side gear, pinion gear, cross pin
• Differential cage, carrier
• Thrust washer
• Oil seal
Clearance between pinion gear and cross pin:
mm (in)
Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm (in)
Standard Limit
φ220mm 0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)
φ
194mm 0.03 - 0.10
(0.001 - 0.004) 0.15 (0.006)


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ISUZU KB P190 2007

4B-36 REAR AXLE
425R300010

Play in splines between the side gear and axle shafts. mm(in)
Standard Limit
φ220mm 0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)
φ
194mm 0.08 - 0.36
(0.003 - 0.014) 0.5 (0.02)
425L100014

Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of
thread to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as illustrated.
Torque : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)



425RW 033


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