lock ISUZU KB P190 2007 Workshop Repair Manual

TRANSFER CASE 7D-21
10. Remove the transfer chain and the front output shaft
from the main shaft.
11. Remove the main shaft snap ring.
12. Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13. Remove the sprocket snap ring.
14. Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.


RTW 37DMF000101
Legend
(8) Thrust W asher
(1) Rear synchronizer spring
(9) Sprocket Snap Ring
(2) Block Ring
(10) Oil Pump ASM
(3) Outside Ring
(11) Oil Pump Retaining Ring
(4) Inside Ring
(12) Retaining Ring
(5) Drive Sprocket
(13) Ball Bearing
(6) Transfer Chain (14) Speedometer Drive Gear
(7) Front Output shaft (15) Main Shaft Snap Ring


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ISUZU KB P190 2007

7D-24 TRANSFER CASE
Internal Component Disassembly and Reassembly

226R300017















H-L Shift Disassembly
1. Remove the guide roller.
2. Use a vise to compress the H-L shift spring (inside the
assembly)





3. Remove the outer snap ring.
4. Remove the shift block assembly from the shift rod.





5. Use a socket and a vise to compress the shift block
spring (inside the assembly)
6. Remove the inner retaining ring.
7. Remove the collar (rear)
8. Remove the shift block spring.
9. Remove the collar (front)
10. Remove the shift block assembly
11. Remove the spring pin.
12. Remove the shift arm.

Legend

(1) Shift Arm
(2) Shift Block Assembly
(3) Inner Retaining Ring
(4) Collar (Front)
(5) Shift Block Spring
(6) Collar (Rear)
(7) Shift Rod
(8) Outer Snap Ring
(9) Guide Roller
(10) Spring Pin

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ISUZU KB P190 2007

TRANSFER CASE 7D-25
H-L shift reassembly
1. Install the shift arm to the shift rod.
2. Install the spring pin. The top of the pin must be flush
with the surrounding surface (no projection).
3. Install the front collar, the spring, and the rear collar to
the shift block in that order.
4. Use a socket and a vise to compress the shift block
spring.
5. Install the inner retaining ring. Be sure that the arm
aperture width is within the specified limit.

226R300014






6. Install the shift lock assembly to the shift rod.
7. Use a socket and a vise to compress the H-L shift
spring.
8. Install the outer snap ring.
9. Install the guide roller.

2-4 shift ASM

226R300016











2-4 shift disassembly
1. Remove the guide roller.
2. Compress the spring and remove the snap ring.
3. Remove the shift arm.
4. Remove the spring.
5. Remove the spring pin.
6. Remove the shift block assembly.
7. Remove the shift rod.

Legend

(1) 25.62 °
(2) 14.1mm Legend
(1) Shift Rod
(2) Shift Arm
(3) Spring
(4) Shift Block Assembly
(5) Spring Pin
(6) Guide Roller
(7) Snap Ring

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ISUZU KB P190 2007

7D-26 TRANSFER CASE
2-4 shift reassembly
1. Install the shift block assembly to the shift rod.
2. Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.

226R300015
3. Install the spring.
4. Install the shift arm.
5. Compress the spring and install the snap ring.
6. Install the guide roller.

Oil pump disassembly
1. Remove the clamps securing the screen.
2. Remove the screen.
3. Remove the clamps securing the hose.
4. Remove the hose.
NOTE: To maintain and protect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Oil pump reassembly

1. Tighten the clamps to secure the hose.
2. Tighten the clamps to secure the screen.
NOTE: Be careful in the direction of clamps.

RTW 37DSH000101
Legend
(1) Oil Pump Assembly
(2) Clamp
(3) Hose
(4) Screen Assembly



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ISUZU KB P190 2007

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

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

7D1-2 TRANSFER CONTROL SYSTEM

Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING.
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR
THE SRS COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE
UNNECESSARY SRS SYSTEM REPAIRS.

CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU/GM will call out those
fasteners that require a replacement after removal.
ISUZU/GM will also call out the fasteners that require
thread lockers or thread sealant. UNLESS OTHERWISE
SPECIFIED, do not use supplemental coatings (Paints,
greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When you
install fasteners, use the correct tightening sequence and
specifications. Following these instructions can help you
avoid damage to parts and systems.


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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-3
General Description







RTW 77DLF000501

Transfer Position and Drive Mode
Three drive modes can be selected through operation of 4W D switch.

Transfer Position 4WD SWITCH Mode Drive mode
2H RW D Rear wheel drive
HIGH
4H 4W D (HIGH) High-speed mechanical
lock-up four wheel drive
LOW 4L 4W D (LOW ) Low-speed mechanical
lock-up four wheel drive
NEUTRAL 2H & 4L (10 Sec) NEUTRAL Towed by other vehicle


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ISUZU KB P190 2007

7D1-46 TRANSFER CONTROL SYSTEM
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shift on the fly) If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz. At the same
time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes out.
Cause of excessive synchronous shifting load
• Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization).
• High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline in transfer case.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and the axle, connecting the front
wheel and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed
∗, the indicator flashes at
a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, check it is safe around the vehicle and then accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.

2. When shifting from 4H to 2H
2-1 When 4WD indicator continues flashing at 2Hz
W hen shifting from 4H to 2H, the 4W D indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed∗. W hen torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle∗ is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, check it is safe around the vehicle and then accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.

∗: Shift on the fly only.


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ISUZU KB P190 2007