Isuzu KB P190. Service manual — part 1209

7D-6 TRANSFER CASE

Transfer Case Front Oil Seal

Transfer Front Oil Seal and Associated Parts

RTW67DMF000301

Legend

(3) O-ring

(1) Front Propeller Shaft

(4) Output Flange

(2) End Nut

(5) Front Oil Seal

Removal

1. Disconnect the battery ground cable.

2. Raise and support the vehicle with suitable stands.

3. Place a suitable sized drain tray under the transfer

case.

4. Remove the drain plug and drain the transfer case oil.

5. Remove the filler plug.

6. Remove the front propeller shaft.

7. Use a flange holder (5-8840-0133-0) to remove the

end nut from the front output shaft then remove the

O-ring and the output flange.

8. Remove the front oil seal from the front cover.

RTW77DSH000201

TRANSFER CASE 7D-7

Installation

1. Thoroughly clean around the oil seal bore in the 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) or

equivalent to the oil seal lip.

3. Tap the oil seal in to place, use an oil seal installer

(5-8840-2785-0) and a soft hammer.

RTW77DSH000301

4. Install the output flange to the front output shaft.

5. Apply the engine oil to the new O-ring and install it to

the front output shaft.

6. Secure the output flange with a flange holder

(5-8840-0133-0).

7. Install the new end nut and tighten them to specified

torque.

Front coupling driver fixing nut torque:

137 N

⋅⋅⋅⋅m (14.0 kgf⋅⋅⋅⋅m/101 lb⋅⋅⋅⋅ft)

8. Use a punch (5-8840-2293-0) to caulk the end nut.

226R300012

RUW34DSH000301

Legend

(1) MAX 26mm (1.02in)

(2) MIN 4mm (0.16in)

7D-8 TRANSFER CASE

9. Install the drain plug to the transfer case and tighten it

to the specified torque.

Drain plug torque: 39 N

⋅⋅⋅⋅m (4.0 kgf⋅⋅⋅⋅m/29 lb⋅⋅⋅⋅ft)

Transfer oil volume: 1.3 lit. (1.37 US qt)

10.

Install the filler plug and tighten it to the specified

torque:

Filler plug torque: 39 N

⋅⋅⋅⋅m (4.0 kgf⋅⋅⋅⋅m/29 lb⋅⋅⋅⋅ft)

11. Install the front propeller shaft.

Propeller shaft bolts torque:

59 N

⋅⋅⋅⋅m (6.0 kgf⋅⋅⋅⋅m/43 lb⋅⋅⋅⋅ft)

12. Lower the vehicle to the ground.

13. Connect the battery ground cable.

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) or

equivalent to the oil seal lip.