differential ISUZU KB P190 2007 Workshop User Guide

REAR AXLE 4B-5
Differential
N⋅m (kgf ⋅m/lb ⋅ft)

RTW 74BMF000101


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

REAR AXLE 4B-7
REAR AXLE ASSEMBLY
General Description
A03R300001

The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the cente
r
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The φ220 mm (8.6 in) or φ194mm (7.6 in) ring gea
r
rear axle uses a conventional ring and pinion gear set
to transmit the driving force of the engine to the rea
r
wheels. This gear set transfers this driving force at a
90 degree angle from the propeller shaft to the drive
shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered rolle
r
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with
12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings, which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

REAR AXLE 4B-9
REAR AXLE
1. Refer to Section 3E “W HEELS and TIRES” for
road wheel Disassembly procedure.
2. Refer to Section 5 “BRAKE” for rear brake removal procedure.





RTW 54BLF000401
Legend
1. Brake Drum
2. Bolt and Nut
3. Axle Shaft Assembly with Brake
4. Shim
5. Snap Ring
6. Axle Shaft
7. Retainer (with ABS)
Retainer (without ABS)
8. Double Taper Roller Bearing

9. Oil Seal
10. Bearing Holder
11. Rear Brake
12. Bolt and Nut
13. Differential Assembly
14. Rear Axle Case Assembly
15. W heel Pin
16. Axle Case Oil Seal
17. Front

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

4B-10 REAR AXLE
Disassembly
• Raise vehicle to the working level.
• Support the axle assembly with the proper jack
and chassis stands.
• Remove wheel and tire.
• Drain differential oil.
• Remove propeller shaft. (Refer to the section
“Rear Propeller Shaft”.)

1. Remove brake drum.
2. Remove ABS sensor. (Refer to the section “ABS”.)
3. Remove brake pipe from wheel cylinder.

420R300003



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-15
Reassembly
1. Using the oil seal installer 5-8840-2202-0 and
grip 5-8840-0007-0, install new axle case oil seal.




RTW 54BSH000301

Note :
Confirm that the dimension : A should be 34.5 –
36.1 mm (1.36 – 1.42 in)







A03R300004

2. Install new oil seal in bearing holder, using the oil seal installer 5-8840-2404-0.






RTW 54BSH000501
Legend
1. Oil Seal
2. Bearing Holder


3. Drive wheel pin into axle shaft flange, using a hammer.
4. Differential assembly a. Clean the mating surface of axle case and differential carrier.
b.
Apply Three Bond 1215 (TB1215) or
equivalent on the surface of differential
assembly as flowing illustration.


RTW 74BSH000301
Legend
a. 3 mm (0.12 in)

c. Tighten bolts and nuts to the specified torque.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

REAR AXLE 4B-19
17. Install brake pipe and ABS sensor and tighten it
to the specified torque.
Torque : ABS Sensor 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
Brake Pipe 16 N ⋅m (1.6 kgf ⋅m/12 lb ⋅ft)
420R30003

18. Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19. Install brake drum.
• Install propeller shaft. (Refer to Section “Rea
r
Propeller Shaft”.)
• Refill differential oil.
• Install wheel and tire.
• Lower vehicle.




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

4B-20 REAR AXLE
DIFFERENTIAL ASSEMBLY
Disassemble View
Legend
1. Bolt
2. Bearing Cap
3. Differential Cage Assembly
4. Side Bearing Outer Race
5. Side Bearing
6. Adjust Shim
7. Flange Nut
8. Flange Assembly
9. Drive Pinion Shaft Assembly

415RY00005

10. Collapsible Spacer
11. Inner Bearing
12. Adjust Shim
13. Oil Seal
14. Outer Bearing
15. Inner Bearing Outer Race
16. Outer Bearing Outer Race
17. Differential Carrier




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

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