Isuzu KB P190. Manual — part 1217

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)

RTW77DSH000201

41. Use a punch (5-8840-2293-0) to caulk the front

companion flange end nut.

226R300012

RUW34DSH000301

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.

TRANSFER CASE 7D-39

43. Use an installer (5-8840-2787-0) to install the main

shaft end snap ring to the rear output shaft (from the

back end of the shaft). Be absolutely sure that the

snap ring is seated in the groove.

226R300022

44. Use an installer (5-8840-2786-0) to install the rear

output oil seal to the rear case.

RTW77DSH000401

220R300021

45. Install the detent balls, the detent springs, and the

detent plugs (2 parts each) to the transfer case.

Tighten the plugs to the specified torque.

Detent plug torque: 19 N·m (1.9 kgf·m/14 lb·ft)

46. Install the neutral switch (black harness cover) to the

transfer case and tighten the bolts to the specified

torque.

Neutral switch bolt torque:

39 N·m (4.0 kgf·m/29 lb·ft)

47. Install the 2-4 switch (gray harness cover) to the

transfer case and tighten the bolts to the specified

torque.

2-4 switch bolt torque: 39 N·m (4.0 kgf·m/29 lb·ft)

48. Install the switch bracket to the transfer case and

tighten the bolts to the specified torque.

Switch bracket bolt torque:

15 N·m (1.5 kgf·m/11 lb·ft)

49. Install the transfer actuator assembly to the transfer

case and tighten the bolts to the specified torque. The

actuator must be installed in the same direction as the

shaft.

Transfer actuator assembly bolt torque:

22 N·m (2.2 kgf·m/16 lb·ft)

50. Install the breather hose between the transfer

actuator and the transfer case.

51. Install the speedometer driven gear, the speedometer

bushing, and the speedometer stay to the transfer

case. Tighten the bolts to the specified torque. (M/T:

MUA, MUX, A/T: JR405E, AW30-40LE)

Speedometer bolt torque:

15 N·m (1.5 kgf·m/11 lb·ft)

7D-40 TRANSFER CASE

52. Install the speed sensor to the transfer case and

tighten the specified torque. (M/T: AR-5, A/T: 4L60-E)

Speed sensor torque: 17 N·m (1.7 kgf·m/12 lb·ft)

53. 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)

54. Loosen and remove the filler plug. Add the specified

volume of transfer oil (5W-30) or the equivalent to the

transfer through the filler hole.

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

55. Replace the filler plug and tighten it to the specified

torque.

Filler plug torque: 39 N·m (4.0 kgf·m/29 lb·ft)

56. Install the underguard and tighten the bolts to the

specified torque.

Underguard bolt torque:
39 N·m (4.0 kgf·m/29 lb·ft)

TRANSFER CASE 7D-41

Main Data and Specifications

General Specifications

Type

Synchronized type gears shifting between the 2 and 4 wheel drive mode.

Planetary type gears shifting between “low" and “high".

Control method

Remote control with the button switch on the instrument panel for gears
shifting among “2H", “4H" and “4L".

Gear ratio

High; 1.000

Low; 2.482

Oil capacity

1.3 lit. (1.37 US qt)

Type of lubricant

BESCO GEAR OIL TRANSAXLE (5W-30)

Refer to Section 0B

Torque Specifications

N

⋅m (kgf⋅m/lb⋅ft)

RTW67DLF000201