transfer case ISUZU KB P190 2007 Workshop Service Manual

TRANSFER CASE 7D-9
Transfer Case Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts

220R300018
Legend

(1) Rear Propeller Shaft
(2) Rear Oil Seal

Removal

1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Remove the rear propeller shaft.
4. Remove the oil seal from the transfer case.

Installation
1. Thoroughly clean around the oil seal bore in the
transfer case and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.


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7D-10 TRANSFER CASE
3. Tap an oil seal in to place, use an oil seal installer
5-8840-2786-0 and a soft hammer.





RTW 77DSH000401




220R300021
4. Install the rear propeller shaft.
Propeller shaft bolts torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)
5. Lower the vehicle to the ground.
6. Connect the battery ground cable.



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TRANSFER CASE 7D-11
Transfer Case Assembly
Transfer Case Assembly and Associated Parts




RTW 57ALF000201
Legend

(1) Rear Propeller Shaft

(2) Front Propeller Shaft

(3) Transfer Case Assembly



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7D-12 TRANSFER CASE
Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2W D using the 4W D push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove rear propeller shaft and front propeller shaft.
NOTE: Apply alignment marks on the flange at both front
and rear sides.
4. Disconnect harness connectors and clip.
Connector: transfer switch, 2W D-4W D actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the ON
position when the 2W D-4W D connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4W D INDICATOR will
light).
5. Remove transfer case assembly from the vehicle.
Installation

1. Apply a thin coat of molybdenum disulfide grease to
the input shaft spline as shown in the figure.

260R300001


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TRANSFER CASE 7D-13
2. Install transfer case assembly to the transmission.
Tighten transfer bolts as shown in the figure.

For M/T (MUA, MUX)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)





RTW 77DLF000201

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7D-14 TRANSFER CASE
For A/T (JR405E, AW30-40LE)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)





RTW 77DLF000301

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TRANSFER CASE 7D-15
For M/T (AR-5), A/T (4L60-E)
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)
mm (in)





RTW 77DLF000401
3. Connect harness connectors and clip.
Connector: transfer switch, 2W D-4W D actuator,
speed sensor.
4. Install rear propeller shaft and front propeller shaft.
Propeller shaft torque: 59 N ⋅
⋅⋅
⋅
m (6.0 kgf ⋅
⋅⋅
⋅
m/43 lb ⋅
⋅⋅
⋅
ft)



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7D-16 TRANSFER CASE
Transfer Control Unit
RHD









RTW 77DMF000101
Legend

(1) Transfer Control Unit

(2) Nut



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TRANSFER CASE 7D-17
LHD











RTW 77DMF000101
Legend

(1) Transfer Control Unit

(2) Nut


Removal
1. Disconnect the battery ground cable.
2. Disconnect the harness connector from the Transfe
r
control unit.
3. Remove the Transfer control unit.
Installation

1. Install the Transfer control unit.
Transfer control unit torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
2. Connect the harness connector to the Transfe
r
control unit.
3. Connect the battery ground cable.



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7D-18 TRANSFER CASE
Transfer Disassembly



RTW 67DLF000101
Legend

(1) Transfer Case Speedometer Bushing, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut
(8)
(M/T: MUA, MUX, A/T: JR405E, AW 30-40LE)
(3) Stoneguard (9) Speed sensor (M/T: AR-5, A/T: 4L60-E)

(4) Detent Plug, Spring and Detent Ball (10) Transfer Actuator (Diesel Engine)
(5) 2-4 Switch ASM (11) Transfer Actuator (Gasoline Engine)
(6) Switch Bracket (12) Breather Hose
(7) Neutral Switch ASM (13) Heat Protector (Gasoline Engine)

Removal

1. Remove the stoneguard.
2. Remove the drain plug from the transfer case to drain
the oil.
3. Remove the parts listed below.
• Speedometer bushing, plate, and speedomete
r
driven gear (M/T: MUA, MUX, A/T: JR405E,
AW 30-40LE)
• Speed sensor (M/T: AR-5, A/T: 4L60-E)

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ISUZU KB P190 2007