1000 ISUZU KB P190 2007 Workshop User Guide

3D-12 REAR SUSPENSION
Reassembly
1. Apply grease to both faces of each leaf spring at
reassembly.
2. Set the leaf springs, aligning them to the setting mark made
before disassembly.

F03L100006
3. Assemble the leaf springs using a bench press.
4. Apply grease to the outside of the bushing.
Install a new center bolt and tighten it to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
29 (3.0/22)
5. Install the bushing using a bench press and a suitable metal fitting.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

4A-12 PROPELLER SHAFT
Removal and Installation

401RS023
Removal
1. Raise the vehicle on a hoist.
NOTE:
Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.

2. Remove center bearing fixing bolt.
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.

NOTE:
Plug the hole of the transmission rear end to prevent oil
leakage.

401L100007
Installation
NOTE:
Cover the slip yoke with cloth to avoid damage to the oil seal
contact surface, when removing propeller shaft from
transmission. Do not damage the oil seal contact surface of
slip yoke with other parts at removal and installation.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.

1.
Align the mark which is applied at removal and insert the
propeller shaft in the transmission.
2. Install rear propeller shaft and tighten the bolts to the specified torque.
Torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
3. Install center bearing and tighten the bolts to the specified torque.
Torque: 69 N ⋅
⋅⋅
⋅
m (7.0 kgf ⋅
⋅⋅
⋅
m/51 lb ⋅
⋅⋅
⋅
ft)



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

REAR AXLE 4B-13
17. Remove double taper roller bearing, oil seal,
bearing holder, and back plate from axle shaft b
y
means of a press.
• Discard used oil seal, double taper rolle
r
bearing, snap ring, retainer.




RTW 54BMH000201
Legend
1. Bench Press Fitting
2. Axle Shaft


18. Oil seal is removed from bearing holder.

19. Bearing outer race is removed from bearing
holder.
• W hen it cannot remove by hand, bearing
outer race is removed using installer 5-8840-
2119-0 and grip 5-8840-0007-0.




RTW 54BSH000701
20. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
• φ 194mm differential assembly has three kinds
of bolts.
Note the installation holes.
21. Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
22. Remove axle case oil seal.
• Discard used oil seal.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

REAR AXLE 4B-21
Disassembly
1. Using holding fixture 5-8840-0275-0 and holding
fixture base 5-8840-0003-0, fix the differential
assembly to the bench.
425L100007

2.
Apply a setting mark to the side bearing cap and
the differential carrier then remove bearing cap.

425RS009

3. Remove differential cage assembly.
4. Remove side bearing outer race. After removal,
keep the right and left hand side bearing
assemblies separate to maintain inner and oute
r
race combinations.
5. Remove side bearing by using remover 5-8840-
0013-0, 5-8840-0014-0, adapter 5-8840-2196-0
(for φ220mm) and 9-8521-1743-0 (for φ194mm).
φ
φφ
φ
220mm



RTW 54BSH000101
φ
φφ
φ
194mm





RTW 54BSH000201

6. Note the thickness and position of the shims then
remove adjust shim.
7. Remove the flange nut by using pinion flange holder 5-8840-0133-0 after raising up its staked
parts completely.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

4B-24 REAR AXLE
Reassembly
1. Install outer bearing outer race by using installer
5-8840-2164-0 (φ220mm), 9-8522-1141-0 ( φ194
mm) and grip 5-8840-0007-0.

φ
φφ
φ
220mm
425L100002
φ
φφ
φ
194mm


425R300001

2. Install inner bearing outer race by using installe
r
5-8840-2163-0 ( φ220mm), 9-8522-1274-0 ( φ194
mm) and grip 5-8840-0007-0.

425L100003
φ
φφ
φ
194mm




425R300002

3.
Adjust the drive pinion mounting distance as
follows:
a.
Apply gear oil to the inner and outer drive
pinion bearing. Clean the pinion setting gauge
set. Then install the gauge set together with
the inner and outer bearings.
Install gauge plate 5-8840-2166-0 ( φ220mm)
and 5-8840-2087-0 ( φ194mm) (3), inner pilot
5-8840-0129-0 ( φ220mm) (2), stud and nut 5-
8840-0127-0 ( φ220mm) and 5-8840-2089-0
( φ 194mm) (4) and outer pilot 5-8840-2085-0
( φ 220mm and φ194mm) (1) through inner and
outer bearings.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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.


BACK TO CHAPTER INDEX
TO MODEL INDEX
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.



BACK TO CHAPTER INDEX
TO MODEL INDEX
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.


BACK TO CHAPTER INDEX
TO MODEL INDEX
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



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007