Isuzu KB P190. Manual — part 1215

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)

220RW035

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)

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).

RTW77DSH000301

2. Use a press to install the ball bearings to the front

output shaft. Be sure that the bearings are fully

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

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 gear

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.

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 synchronizer

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