ISUZU KB P190 2007 Workshop Repair Manual

SHIFT ON THE FLY SYSTEM 4C2-3
SHIFT ON THE FLY ELECTRICAL EQUIPMENT
Axle Shaft Connection and Disconnection
RUW 34BMF000101
Actuator Assembly





412RY00004



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4C2-4 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM AND ASSOCIATION PARTS








RTW 440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.


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SHIFT ON THE FLY SYSTEM 4C2-5



Disassembly
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear





412RW 017
10. Snap Ring
Remove snap ring from front axle case by using a snap ring pliers.
11.Inner Shaft
Take out inner shaft from front axle case.





412RW 016
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring pliers.





412RW 015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and press.
Remover : 5-8840-2197-0
NOTE:
Be careful not to damage the shaft.

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ISUZU KB P190 2007

4C2-6 SHIFT ON THE FLY SYSTEM





412RS045
14.Needle Bearing
Remove needle bearing from inner shaft by using a special tool.
Remover : 5-8840-0027-0
Sliding hammer : 5-8840-0084-0
NOTE:
Be careful not to damage the shaft.
15.Oil Seal
Remove oil seal from front axle case.
NOTE:
Be careful not to damage the front axle case.

Inspection and Repair
Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.

Visual Check
• Check and see if the inner shaft has such
abnormalities as wear and damage.








412RW 014





412RS008
•
W hen inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormalit
y
in its gear part (a slide with sleeve), replace the shaft.


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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-7















412RS026
Inner Shaft Run-Out
W ith both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit) mm (in)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.






RTW 440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smooth less is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smooth less, replace the
needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or checking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.











412RW 011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smooth less is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.






412RW 022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

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4C2-8 SHIFT ON THE FLY SYSTEM




RTW 440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, o
r
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as smooth less when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.





RTW 440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)




RTW 440SH000501




RTW 440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or othe
r
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.

State Port 3Port 4Port 1, 2
Conducting Function
A
+ −
−−
−
C
B −
−−
−
+ × D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

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SHIFT ON THE FLY SYSTEM 4C2-9



RTW 440SH000601









RTW 440SH000801
Dimension Check
Measure illustration sized A, B, and C
Limit mm (in)

A 64.3 (2.53)
B 6.7 (0.26)
C 6.7 (0.26)













RTW 440SH000701




Reassembly
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer 5-8840-2407-0
Grip 5-8840-0007-0

























412RS051



14. Needle Bearing
Force a new needle bearing into inner shaft by using a
special tool.
Installer : 5-8840-2408-0
Grip : 5-8840-0007-0

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ISUZU KB P190 2007

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing
• Place a new snap ring in inner shaft.
• Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft • Clean the housing contact surface of the front axle
case.
• Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.






412RW 017
10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear Apply differential gear oil to clutch oil.
8. Sleeve Apply differential gear oil to sleeve.






412RW 023


7. Housing
• Clean contact surface with the front axle and actuato
r
mounting surface.
•
Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
75 (7.6/55)

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SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator • Clean the actuator contact surface with the housing.
•
Apply liquid gasket to the contact surface on the
actuator side.
• Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N⋅m (kgf ⋅m/lb ⋅in)
9 (0.9/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt • Install front axle drive shaft and mounting bracket.
• Tighten fitting bolts to specified tightening torque.
Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
116 (11.8/85)
1. Filler Plug • Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal) 0.12 (0.03/0.03)
• Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque N⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0/58)



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4C2-12 SHIFT ON THE FLY SYSTEM
Torque Specifications N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m / lb ⋅
⋅⋅
⋅
ft)







RTW 440LF001501

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ISUZU KB P190 2007