differential ISUZU KB P190 2007 Workshop Owner's Guide

REAR AXLE 4B-45
TROUBLESHOOTING


Refer to this Section to quickly diagnose and repai
r
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise 1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage 1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the W heels (Propeller Shaft Operation is Normal)







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ISUZU KB P190 2007

4B-46 REAR AXLE
1. ABNORMAL REAR AXLE NOISE
1) Noise when the Engine is Driving the Vehicle

Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil
NG
Differential side bearingAdjust the differential side
bearing preload
Replace the drive pinion
bearings
Adjust the drive pinion bearing
preload
Replace the gear oil
Loose differential side
bearings
W orn drive pinion bearings
Loose drive pinion bearings
W rong or poor grade gear oil
Drive pinion to ring gear
backlash
Drive pinion end play
Adjust the backlashToo much or too little backlash
Continued on the next page OK
OK
NG
NG
NG
NG
NG
OK
OK
Rear axle gear oil
Replace the differential side
bearingsW orn differential side bearings
NG


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ISUZU KB P190 2007

4B-48 REAR AXLE
3) Intermittent Noise

Checkpoint Trouble Cause Countermeasure



Axle case inside


Ring gear


Remove the foreign material


Replace the drive pinion and
the ring gear as a set


Foreign material in the axle
case


W arped ring gear


Differential cage

Tighten the differential cage
bolts


Replace the shaft


Loose differential cage bolts


Too much spline play

OK NG
NG
NG
NG
OK
OK
Axle shaft



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ISUZU KB P190 2007

REAR AXLE 4B-49
4) Noise when the Vehicle is Turning

Checkpoint Trouble Cause Countermeasure



Differential cross pin


Side gear


Replace the differential cross
pin


Replace the side gear


W orn differential cross pin


W orn side gear


Differential pinion

Replace the differential pinion


Replace the rear axle shaft


W orn differential pinion


W orn rear axle shaft splines

OK NG
NG
NG
NG
OK
OK
Rear axle shaft



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ISUZU KB P190 2007

4B-52 REAR AXLE
3. OIL LEAKAGE
1) Differential Carrier Leakage

Checkpoint Trouble Cause Countermeasure

Correct the oil levelToo much gear oil
NG
Reapply the liquid gasket
and/or tighten the lock nut to
the specified torque
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Replace the oil seal
Ring gear thrust boltLoose lock nut and/or liquid
Liquid gasket seal bed
Loose bolts
Oil sealW orn or defective oil seal
Differential carrier
Clean the air breatherAir breatherClogged air breather
NG
NG
NG
NG
NG
OK
OK
OK
OK
Gear oil level



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REAR AXLE 4B-53
2) Axle Case Leakage

Checkpoint Trouble Cause Countermeasure

Tighten the drain plug and/or
replace the gasket(s)Loose drain plug and/or
defective gasket(s)
NG
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Clean the air breather
Liquid gasket seal bad
Loose bolts
Air breatherClogged air breather
Differential carrier
Replace the axle caseAxle caseCracked axle case
NG
NG
NG
NG
OK
OK
OK
Oil filler and drain plug



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ISUZU KB P190 2007

REAR AXLE 4B-55
4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)

Checkpoint Trouble Cause Countermeasure

Replace the rear axle shaftBroken rear axle shaft
NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider
NG
NG
OK
OK
Rear axle shaft













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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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FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) φ
φφ
φ
194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 3.583, 3.727, 3.909, 4.100, 4.300, 4.555, 4.777, 5.125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.31)
Axle shaft type Constant velocity joint (Barfield joint type and double offset joint).


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FRONT WHEEL DRIVE 4C1-5
FRONT DIFFERENTIAL
N⋅m (kgf ⋅m/lb ⋅ft)





RTW 440LF000901


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