wheel bolts ISUZU KB P190 2007 Workshop User Guide

WHEELS AND TIRES 3E-3
TORQUE SPECIFICATIONS
SPECIAL PARTS FIXING NUTS AND BOLTS
WHEELS AND TIRES
N⋅m (kgf ⋅m/lb ⋅ft)






RTW 73ELF000101



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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.

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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.



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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.


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FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing ...................................................................................................................... ...... 4C1- 7
General Description .......................................................................................................... 4C 1- 8
Front Drive Axle Assembly ..............................................................................................4C1- 10 Front Drive Axle Assembly and Associated Parts ....................................................4C1- 10
Removal ........................................................................................................................ 4C1- 11
Installation ................................................................................................................... .4C1- 12
Front Axle Drive Shaft ......................................................................................................4C1 - 14
Front Axle Drive Shaft and Associated Parts ............................................................4C1- 14
Disassembly .................................................................................................................4C1 - 15
Inspection and Repair .................................................................................................4C1- 16
Bushing Replacement ................................................................................................4C1- 17
Reassembly ..................................................................................................................4C1 - 17
Standard Caulk Measure ............................................................................................4C1- 18
Differential................................................................................................................... ......4C1- 20
Disassembly .................................................................................................................4C1 - 20
Major Components ................................................................................................4C1- 20
Minor Components ................................................................................................4C1- 23
Inspection and Repair .................................................................................................4C1- 25
Reassembly .................................................................................................................4C1 - 27
Minor Components..................................................................................................4C1- 27
Major Components ..................................................................................................4C1- 29

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4C1-4 FRONT WHEEL DRIVE
SPECIAL PARTS FIXING NUTS AND BOLTS
FRONT DRIVE AXLE AND PROPELLER SHAFT
N⋅m (kgf ⋅m/lb ⋅ft)




RTW 74CMF000101

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4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacture Remarks

RTV* Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
W ater Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket. Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262
Red 2. Apply LOCTITE to the bolts.


LOCTITE 270
Green

LOCTITE 271
Red
3. Tighten the bolts to the specified torque.
4. W ait at least on hour before continuing the installation procedure.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-11

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front W heel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in this section.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.


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ISUZU KB P190 2007

4C1-12 FRONT WHEEL DRIVE

17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is supported securely.
2. Be careful not to damage the bellows of the power steering unit by interference.
3. Be careful not to damage the breather pipe and breather pip bracket of the shift on the fly by
interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power steering unit by interference.
2. Be careful not to damage the breather pipe and breather pip bracket of the shift on the fly by
interference.
3. When installing the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle.

RTW 34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kgf·m/124 lb·ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5.
Align the bolt hole of the lower control arm, install the bolts
and nuts.

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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-13


NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kgf·m/73 lb·ft)
9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque.
Torque : 93 N·m (9.5kgf·m/69 lb·ft)
10. Install lower nuts of the stabilizer link, tighten it to the specified torque.
Torque : 50 N·m (5.1kgf·m/37 lb·ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake system.
16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque.
Torque : 226 N·m (23.0kgf·m/166 lb·ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Front Alignment section.
20. Tighten the bolts and nuts of the lower control arm to the specified torque.
Refer to Lower Control Arm in Suspension section.


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ISUZU KB P190 2007