transfer case ISUZU KB P190 2007 Workshop Manual PDF

TRANSFER CASE 7D-29
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard: 2.46-2.74 mm (0.097-0.108 in)
Limit: 3.0 mm (0.118 in)
226RS037

2WD-4WD Synchronizer (3-Cone)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2W D-4W D synchronizer assembly must be replaced.
Block ring and dog teeth clearance
Standard: 1.5 mm (0.059 in)
Limit: 0.8 mm (0.031 in)

226R300019

Clutch Hub and Insert Clearance

1. Clutch Hub and Insert Clearance
2. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
3. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard: 0.01-0.19 mm (0.0004-0.0075 in)
Limit: 0.3 mm (0.012 in)

226RS038

Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.


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ISUZU KB P190 2007

7D-30 TRANSFER CASE
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard: 23.4 mm (0.92 in)
Limit: 22.8 mm (0.90 in)

220RW 035

Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent ball
Compressed height: 18.7 mm (0.736 in)
Standard: 68.6-88.2 N (7.0-9.0 kg/ 15.4-19.8 lb)

220RS013

Shift Arm

1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.

Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
H-L Shift arm thickness
Standard: 7.6-7.85 mm (0.299-0.309 in)
Limit: 7.0 mm (0.276 in)
2-4 Shift arm thickness
Standard: 9.6-9.85 mm (0.378-0.388 in)
Limit: 9.0 mm (0.354 in)


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ISUZU KB P190 2007

TRANSFER CASE 7D-31
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is reassembled.
1. Use an oil seal installer (5-8840-2785-0) to press the
new input shaft and/or front output shaft oil seals into
place (If replacement is required).






RTW 77DSH000301
2. Use a press to install the ball bearings to the front
output shaft. Be sure that the bearings are full
y
inserted and then install the snap ring.
3. Install the damper ring and the internal gear to the
transfer case. Be sure that the damper ring is
between the internal gear and the case.

226R300004






Note the direction of the dumper ring installation as
figure.

226R300025
Legend

(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring

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7D-32 TRANSFER CASE
4. Use a press and an installer (5-8840-2784-0) to hold
the internal gear against the damper ring. Install the
retaining ring (spiral type).





5. Use a press and an installer (5-8840-2782-0) to force
the needle bearing fully into the carrier and gear
assembly.





6. Use a press and an appropriate special tool to force
the ball bearings fully into the carrier and gear
assembly.





7. Install the carrier snap ring.
8. Install the thrust needle bearing, the sun gear input
shaft, the needle bearing, the planetary dog teeth, and
the dog teeth snap ring to the carrier and gea
r
assembly in that order.
9. Install the outer retaining ring to the transfer case
10. Use a pair of snap ring pliers to install the carrier and gear assembly.
NOTE: Be sure that the outer retaining ring fits snugly in
its groove.


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TRANSFER CASE 7D-33
226R300003










11. Use a press to install the 2-4 hub.





12. Install the hub snap ring.
13. Install the synchronizer key springs, the synchronize
r
key, and the 2-4 sleeve to the 2-4 hub. The key and
the open end of the springs must be facing in the
opposite direction.

Legend

(1) Retaining Ring
(2) Carrier and Gear ASM
(3) Thrust Needle Bearing
(4) Sungear Input Shaft
(5) Planetary Dog Teeth
(6) Dog Teeth Snap Ring

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7D-34 TRANSFER CASE
14. Insert the H-L sleeve into the main shaft.


226R300023
Legend

(1) H-L Sleeve
(3) Synchronizer Key and Key Spring

(2) 2-4 Sleeve


15. Install the sleeve to the H-L shift assembly.
16. Install the sleeve to the 2-4 shift assembly.
17. Coat the area around each of the shift assembl
y
insertion holes (transfer case) with transfer oil.
18. Install the main shaft together with the H-L shift
assembly and the 2-4 shift assembly to the shift drum.



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TRANSFER CASE 7D-35
19. Align the shift shaft splines with the shift drum and
install the shafts to the drum.


RTW 320MF000201
Legend

(1) H-L Sleeve and Shift ASM
(3) Shift Shaft

(2) 2-4 Sleeve ASM with Main Shaft and Shift ASM (4) Shift Drum


NOTE: Be careful in the direction of an assembly.

P1010041/020124
20. Coat the main shaft with oil.
21.
Align the block ring, the outside ring, and the inside
ring with the 2-4 hub assembly and install them.
22. Assemble the sprocket, transfer chain, and front
output shaft.
23. Install the sprocket, transfer chain, and front output
shaft to the main shaft and the transfer case.


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7D-36 TRANSFER CASE
24. Align the sprocket thrust washer with the main shaft
groove and install it.

226R300009

25. Select a snap ring that will allow minimum axial play.
Insert it to the main shaft installation groove.
mm (in)
Snap ring thickness Identification color
2.15 (0.085) Red
2.10 (0.083) Not colored
2.05 (0.081) Blue
2.00 (0.079) White

226R300008


Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) Sprocket
(5) Transfer Chain
(6) Front Output Shaft
(7) Thrust W asher
(8) Snap Ring

26. Measure the snap ring external diameter. If the
measured diameter is outside the specified range, a
larger or smaller snap ring must be used.
Snap ring outside diameter (Standard):
53.0 ±
±±
±
0.5 mm (2.09 ±
±±
±
0.02 in)
27. Position the rear cover so that its mating surfaces are
facing up.
28. Use a press and an installer (5-8840-2783-0) to install
the front output shaft needle bearing. The installe
r
must be aligned with the bearing manufacturer's
name (stamped into the bearing).





29. Install the oil pump wire snap ring to the rear cover.


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TRANSFER CASE 7D-37
226R300005



30. Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31. Use a press and an installer (9-8522-1268-0) to install
the rear output shaft ball bearings. Do not drive the
ball bearings into place with a hammer.





32. Install the rear output shaft retaining ring.
33. Place the oil pump in its specified position.
34. Secure the oil pump strainer to the rear cover and
tighten the bolts to the specified torque.
Oil pump and rear cover bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)


226R300010










35.
Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
Legend

(1) Oil Pump Assembly
(2) W ire Snap Ring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend
(1) W ire Snap Ring

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7D-38 TRANSFER CASE
226R300011
36. Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 N ·m (2.2 kgf ·m/16 lb ·ft)
37. Apply engine oil to the companion flange O-ring.
38. Install the O-ring to the front output shaft.
39. Secure the front companion flange with a flange
holder (5-8840-0133-0).
40. Install the end nuts and tighten them to the specified
torque.
Front companion flange end nut torque:
137 N ·m (14.0 kgf ·m/101 lb ·ft)


RTW 77DSH000201

41. Use a punch (5-8840-2293-0) to caulk the front
companion flange end nut.
226R300012
RUW 34DSH000301

Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)

42.
Apply Loctite 575 to the threaded portion of the
detente plugs.


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ISUZU KB P190 2007