brake ISUZU KB P190 2007 Workshop Owner's Manual

REAR SUSPENSION 3D-7
F03L100003

Removal
• Jack up the rear axle and place chassis stands under the
frame near the front end of the rear spring brackets.
Note:
• Be careful not to stretch the flexible brake hose o
r
parking brake cable.
• Support the vehicle on the specified jack point.
1. Remove the parking brake cable from the leaf spring.
2. Loosen the shock absorber fixing nut and remove the nut and special washer from the lower clamp.


3. Remove the shock absorber fixing nut and washer at frame
side.
4. Lifting the rear axle using a jack, remove the shock
absorber and lower the jack.
5. Remove the U bolt fixing nut.
6. Take out the U bolt, seat and lower clamp.
7. Support the leaf spring using a jack and remove the shackle pin fixing nuts.
8. Drive out the shackle pin, using a brass bar and hammer.
9. Remove the shackle plate and rubber bushings.
10. Remove the nut and drive out the shackle using a brass bar and hammer.
11. Remove the leaf spring.
12. Remove the bump rubber.



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3D-10 REAR SUSPENSION
9. Install the parking brake cable on the leaf spring and
tighten the nut at its bracket.
Torque N ⋅m (kgf ⋅m/lb ⋅in)
7 (0.7/61)


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4A-10 PROPELLER SHAFT
4×
××
×
2 M/T AR-5, 4 ×
××
×
2 A/T 4L60-E Model







RTW 64ASF000101
Torque is transmitted from the transmission to the
axle through propeller shaft and universal joint
assembles. All propeller shafts are the balanced
tubular type. A splined slip joint is provided in some
drivelines.
• Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted.
•
Alignment marks should be applied to each
propeller shaft before removal.
• Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.
• Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.


Phasing
The propeller shaft is designer and built with the yoke lugs
(ears) in line with each other. This design produces the
smoothest running shaft possible, called phasing. Vibration can
be caused by an out-of-phase propeller shaft. The propeller
shaft down each time the universal joint goes around. This
vibration would be the same as a person snapping rope and
watching the “wave” reaction flow to the end. A propeller shaft
working in phase would be similar to two persons snapping a
rope at the same time, and watching the “waves” meet and
cancel each other out. In comparison, this would be the same
as the universal joints on a propeller shaft. A total cancellation
of vibration produces a smooth flow of power in the driveline. It
is very important to apply a reference mark to the propeller
shaft before removal, to assure installation alignment.

401RW 015
Universal Joint
A universal joint consists of two Y-shaped yokes (2) connected
by a crossmember called a spider (1).
The spider is shaped like a cross. Universal joints are designed
to handle the effects of various loadings and front or rear axle
windup during acceleration. W ithin the designed angle
variations, the universal joint will operate efficiently and safely.
W hen the design angle is changed or exceeded the
operational life of the joint may decrease.
The bearings used in universal joints are of the needle roller
type. The needle rollers are held in place on the trunnions by
round bearing cups. The bearing cups are held inside the
yokes by snap rings.

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ISUZU KB P190 2007

4A-20 PROPELLER SHAFT
Front Propeller Shaft
Removal and Installation








RUW 54AMF000201

Legend
1. Bolt, Nut and W asher (Front Axle Side)
2. Front Propeller Shaft
3. Nut and W asher (Transfer Side)





401RS020
Removal
1. Jack up the vehicle and support it on the chassis stands.
2. Gear shift lever should be placed in neutral position and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE:
Apply alignment marks on the flange at the front propeller shaft
both front and rear side.
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.

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4B-8 REAR AXLE
SERVICING
Rear Axle Oil Replacement
Oil Capacity liters (US/UK gal.)

Specified gear oil GL5 (API grade)(STD)
GL5LSD (LSD)

φ220mm 2.4 (0.63/0.53)
φ194mm 1.6 (0.42/0.35)
Filler Plug and Drain Plug Torque N ⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0/58)

Axle Shaft Roller Bearing Endplay
Inspection
1. Raise and suitably support vehicle.
2. Remove the wheel and brake drum.
3. Inspect the axle shaft roller bearing endplay using dial gauge.
Endplay mm (in
)
Standard 0 ~ 0.2 (0 ~ 0.008)
If the endplay exceeds 0.2mm (0.008 in), replace the
axle shaft roller bearings.
Refer to Rear Axle Reassembly.

RTW 34BSH000101


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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

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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



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REAR AXLE 4B-11
305R30000
Legend
1. Tension Pin
2. Shoe Clamp Spring
3. Return Spring
4. Shoe Assembly with Parking Brake Lever
5. Shoe Assembly with Adjuster Lever
6. Spring
7. Parking Brake Cable


8. Adjuster
9. Parking Brake Lever
10. Adjuster Spring
11. Adjuster Lever
12. W heel Cylinder
13. Back plate


4. Remove tension pin and shoe clamp spring.
5. Remove return spring.
6. Remove shoe assembly with parking brake lever.
7. Remove shoe assembly with adjuster lever and spring.
8. Remove parking brake inner cable from parking
brake lever.



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4B-12 REAR AXLE
9. Use offset box wrench to compress locking lugs
on the cable, then remove parking brake oute
r
cable from back plate.

311RS012
Legend
1. Offset Box W rench


10. Remove wheel cylinder.
11. Remove bearing holder fixing nuts.
12. Take out axle shaft assembly with back plate and
set it on a bench press as following illustration.
W hen axle shaft is extracted, since axle case oil
seal is damaged, replace the axle case oil seal.
13. Remove snap ring. Use snap ring pliers to
remove. Snap ring is prohibition of reuse.
14. Remove shim (If so equipped)
15. Grind the retainer surfaces using a grinder, then chisel them out with a chisel.



16. Position remover 5-8840-2831-0 on the bearing
holder with 4 nuts.




RTW 54BSH000801


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ISUZU KB P190 2007

REAR AXLE 4B-17
8. Certainly install new snap ring, use snap ring
pliers. W hen transform or damage, replace ne
w
one.




RTW 34BMH000101
Legend
1. Snap ring
2. Crevice
3. Retainer (with ABS)
Retainer (without ABS)


9. Insert a shim of sufficient thickness between
snap ring and end of retainer.

Standard 0 − 0.2 mm (0 − 0.008 in)

Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 mm (0.008 in), it
adjusts so that is may become 0.2 mm (0.008 in)
or less using shim.

Shim Pats No. Thickness

1 9-41519110- ∗ 0.18 mm (0.0071 in)

2 8-97130387- ∗ 0.50 mm (0.0197 in)

Crevice No. of shim Total
mm (in)
1 2 mm (in)
1.0(0.0394)  2 1.00(0.0394)
0.9(0.0354) 2 1 0.86(0.0339)
0.8(0.0315) 1 1 0.68(0.0268)
0.7(0.0276) 1 1 0.68(0.0268)
0.6(0.0236)  1 0.50(0.0197)
0.5(0.0197)  1 0.50(0.0197)
0.4(0.0157) 2  0.36(0.0142)
0.3(0.0118) 1  0.18(0.0071)
0.2(0.0079) 1  0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
a. Clean the mating surface of axle case and bearing holder.
b. Apply Three Bond 1215 (TB1215) o
r
equivalent on the surface of axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the specified torque.
Torque : 84 N ⋅m (8.6 kgf ⋅m/62 lb ⋅ft)
12. Install wheel cylinder and tighten the bolt to the specified torque.
Torque : 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
13. Install parking brake outer cable in back plate and inner cable in parking brake lever.


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ISUZU KB P190 2007