Isuzu KB P190. Manual — part 1216

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 assembly

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.

TRANSFER CASE 7D-35

19. Align the shift shaft splines with the shift drum and

install the shafts to the drum.

RTW320MF000201

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.

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 Washer

(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 installer

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.

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) Wire Snap Ring

(3) Retaining Ring

(4) Ball Bearing

(5) Speedometer Gear Drive Gear

(6) Rear Cover

Legend

(1) Wire Snap Ring