ABS ISUZU KB P190 2007 Workshop Service Manual

3D-18 REAR SUSPENSION
3. SPRING BREAKAGE
Checkpoint Problem Countermeasure


Replace

Oil leakage

NG

Shock absorber


Replace

Bushing worn


U-bolts


Shackle pins and pivot pins


Replace


Retighten


Retighten


Damaged


Bolts and nuts for loosening


Bolts and nuts for loosening


Replace

W orn or damaged

OK
OK
NG
NG
NG
NG
NG
OK

Condition of loading

Continued on the next page

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ISUZU KB P190 2007

4B-6 REAR AXLE
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). Poo
r
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 one hour before continuing the installation procedure.



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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

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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



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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

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.




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ISUZU KB P190 2007

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

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

4C1-38 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4×2 Except High Ride Suspension Model)
Disassembly
Refer to SECTION 3E “W HEELS AND TIRES” for wheel removal procedure.

RTW 34CLF000801
Disassembly Steps
1. Bolt
▲ 2. Brake caliper
▲ 3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer


8. Outer bearing
▲ 9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor
▲ 13. Bolt
▲ 14. W heel pin



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ISUZU KB P190 2007