Isuzu KB P190. Manual — part 1212

7D-18 TRANSFER CASE

Transfer Disassembly

RTW67DLF000101

Legend

(1) Transfer Case

Speedometer Bushing, Plate and Driven Gear

(2) Companion Flange, O-ring and Nut

(8)

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

(3) Stoneguard

(9) Speed sensor (M/T: AR-5, A/T: 4L60-E)

(4) Detent Plug, Spring and Detent Ball

(10) Transfer Actuator (Diesel Engine)

(5) 2-4 Switch ASM

(11) Transfer Actuator (Gasoline Engine)

(6) Switch Bracket

(12) Breather Hose

(7) Neutral Switch ASM

(13) Heat Protector (Gasoline Engine)

Removal

1. Remove the stoneguard.

2. Remove the drain plug from the transfer case to drain

the oil.

3. Remove the parts listed below.

• Speedometer bushing, plate, and speedometer

driven gear (M/T: MUA, MUX, A/T: JR405E,

AW30-40LE)

• Speed sensor (M/T: AR-5, A/T: 4L60-E)

TRANSFER CASE 7D-19

• Breather hose (Between the transfer case and the

transfer actuator assembly)

• Transfer actuator assembly
• Switch bracket
• 2-4 switch assembly (Gray harness cover)
• Neutral switch assembly (Black harness cover)
• Detent plugs, detent springs, and detent balls (2

parts each)

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

end nut from the front companion flange.

RTW77DSH000201

5. Remove the bolts attaching the rear cover to the

transfer case.

6. Strike the area around the front output shaft head and

the rear cover bolt holes with a plastic hammer to

remove the rear cover.

220R300022

7D-20 TRANSFER CASE

7. Remove the parts listed below from the rear cover.

• H-L sleeve
• H-L shift assembly
• 2-4 sleeve, synchronizer key, and front

synchronizer spring (do not remove the rear

spring)

• 2-4 shift assembly
• Shift drum and shift shaft
• Sun gear needle bearing

260R300001

8. Remove the oil pump strainer fixing bolts from the

rear cover.

9. Compress the retaining ring at the rear of the chain.

Strike the rear end of the main shaft with a plastic

hammer to remove the main shaft, transfer chain, and

front output shaft assembly from the rear cover. Be

careful not to damage the oil pump strainer.

226R30001

Legend

(1) Sun Gear Needle Bearing

(2) H-L Sleeve

(3) 2-4sleeve, synchronizer key, and front

synchronizer spring

(4) 2-4 Shift ASM

(5) Shift Shaft

(6) H-L Shift ASM

(7) Shift Drum

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.

RTW37DMF000101

Legend

(8) Thrust Washer

(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