start ISUZU KB P190 2007 Workshop User Guide

FRONT SUSPENSION 3C-51
CAUTION: Be careful not to damage the ball joint
boot.





901RW 271
7. Remove lower ball joint nut.
8. Remove lower ball joint bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with a new one.





450RS026
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N ⋅
⋅⋅
⋅
m (0.25-0.65 kgf ⋅
⋅⋅
⋅
m/1.8-
4.7 lb ⋅
⋅⋅
⋅
ft)







450RS024
• If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install lower ball joint bolt.
3. Install lower ball joint nut and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅
⋅⋅
⋅
ft)
4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

3E-10 WHEELS AND TIRES
TROUBLESHOOTING
Typical examples of abnormal tire tread wear and major causes :

CAUTION:
Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and
other suspension related problems.


Spotty wear - wear localized
on shoulder section. In
extreme cases, the tire
becomes polygonal in shape.
Tire or wheel out of
round or distorted. Hub or knuckle out
of round or distorted. Play in hub bearings
or ball joints. Rotating parts out of
balance.
Tread wear one-sided.
Rotating parts out of
balance. Tire or wheel out of
round. Hub or knuckle out
of round or distorted.
Localized tread wear.
Once spotty wear develops in
tread due to hard braking or
abrupt starting, localized wear
tends to be accelerated.




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ISUZU KB P190 2007

REAR AXLE 4B-3
MAIN DATA AND SPECIFICATIONS
REAR AXLE
Ring gear size mm (in)φ194 (7.94) φ220 (8.66)
Rear axle type Banjo, semi-floating
Rear axle capacity N (kg/lb)18140 (1850/4079)
Rear axle case
Axle tube section

Outside diameter mm (in)80 (3.15)
Thickness mm (in)4.5 (0.118)
Final drive type Single speed
Final gear type Hypoid
Drive pinion bearing preload N⋅m (kgf ⋅cm/lb ⋅in)
Starting torque (At drive pinion flange nut) 0.6-1.1 (6.5-11.5/5.6-10.0) 0.7-1.3 (7.0-13.0/6.1-11.3)
Preload adjusting method Collapsible
Final gear backlash mm (in) 0.13-0.18 (0.005-0.007) 0.15-0.20 (0.006-0.008)
Differential carrier assembly
W eight (Dry) kg/lb22.0/48.5 29.0/63.9
Lubrication
Specified gear oil (APL grade) GL5 GL5 (STD), GL5LSD (LSD)
Oil capacity liter (US/UK gal) 1.6 (0.42/0.35) 2.4 (0.63/0.53)


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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-44 REAR AXLE
Confirmation of Operation
• Using the side gear holder : 5-8840-2682-0,
measure the starting torque of the side gear.
Starting torque : 29-45 N ⋅m (3.0-4.6 kgf ⋅m/22-33
lb ⋅ft)




425RW 065
Legend
1. Side Gear Holder : 5-8840-2682-0






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ISUZU KB P190 2007

4C1-34 FRONT WHEEL DRIVE







12. Flange Nut and Washer

(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion flange holder.
Pinion flange holder : 5-8840-0133-0
Torque N ⋅m (kgf ⋅m/lb ⋅ft
)
177 - 275 (18 - 28/130 - 202)
Discard used flange nut and install new one.






(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is obtained.
Starting Torque N⋅m (kgf ⋅m/lb ⋅in
)
0.63 - 1.13 (0.06 – 0.12/5 - 10)


13. Adjust Shim
(1)
Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.

1 Installer : 9-8522-1164-0
2 Drive handle : 5-8840-0007-0
3 Pilot : 9-8521-1743-0




(2) Insert the differential cage assembly with bearing oute
r
races into the side bearing bores of the carrier.



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


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-43


Important Operations
1. Wheel Pin
(1) Place hub on a wood workbench or a block of wood, approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats completely.



(3) Align index marks and install hub to disc.



2. Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
103 (10.5/76)


3. ABS sensor rotor
(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.


RTW 74CSH000201
4. Inner Bearing and Outer Race
5. Oil Seal
• Outer Bearing Outer Race
(1) Install the bearing outer race by driving into the hub.
Installer (Outer) : 5-8840-2852-0
Installer (Inner) : 9-8522-1270-0
Grip : 5-8840-0007-0


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ISUZU KB P190 2007

4C1-50 FRONT WHEEL DRIVE


Important Operations
1. Wheel Pin
( 1 ) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats completely.



(3) Align index marks and install hub to disc.



2. Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
1 03 ( 10.5/76)


3. ABS sensor rotor
( 1 ) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.



4. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2 119-0
Grip : 5-8840-0007-0


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-59


13. Wheel Pin
( 1 ) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats completely.



(3) Align index marks and install hub to disc.



14. Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
1 03 ( 10.5/76)


15. ABS sensor rotor
( 1 ) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.




16. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2 119-0
Grip : 5-8840-0007-0


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ISUZU KB P190 2007