Isuzu KB P190. Manual - part 1214

7D-26  TRANSFER CASE 

2-4 shift reassembly 

1.  Install the shift block assembly to the shift rod. 

2.  Install the spring pin. The head of the pin must not 

project beyond the surface (1) of the shift block. 

 

226R300015

3.  Install the spring. 

4.  Install the shift arm. 

5.  Compress the spring and install the snap ring. 

6.  Install the guide roller. 
 

Oil pump disassembly 

1.  Remove the clamps securing the screen. 

2.  Remove the screen. 

3.  Remove the clamps securing the hose. 

4.  Remove the hose. 
NOTE:  To maintain and protect oil pump function, the 
pump is constructed so that it cannot be disassembled.

Under no conditions attempt to disassemble the pump.

 

Oil pump reassembly 

1.  Tighten the clamps to secure the hose. 

2.  Tighten the clamps to secure the screen. 

 

NOTE:  Be careful in the direction of clamps. 

 

RTW37DSH000101

 

Legend 

(1) Oil Pump Assembly 

(2) Clamp 

(3) Hose 

(4) Screen Assembly 

 

 

TRANSFER CASE  7D-27 

Inspection and Repair 

1.  Make the necessary repair or parts replacement if 

wear, damage or any other abnormal conditions are 

found during inspection. 

2.  Wash all parts thoroughly in clean solvent. Be sure all 

old lubricant, metallic particles, dirt, or foreign material 

are removed from the surfaces of every part. Apply 

compressed air to each oil feed port and channel in 

each case half to remove any obstructions or cleaning 

solvent residue. 

 

Inspection and Repair (Transfer Case 

Assembly) 

When wear, damage, or any other defects are observed 
during the inspection, the part or parts must be repaired 
or replaced. Wash all the parts with clean detergent, and 
check that old oil, metallic particles, dirt, or foreign 
materials are completely removed. Blow the air into oil 
holes and grooves to remove foreign materials or 
residual detergent. 
 

Chain 

•  Check whether the face that contacts the sprocket is 

free from excessive wear or damage. If defects are 

observed, replace the part. 

•  If the chain interference mark is found on the inside 

wall of the transfer cover or the chain is so slack that a 

skipped engagement occurs between the chain and 

sprocket, replace the chain. 

 

Sprocket 

•  Check whether the sprocket tooth surface is 

excessively worn or damaged, and there is evidence 

of burrs, chipping, wear, or damage on the gear 

spline. Remove minor flaws or scratches with oil 

stone. If excessive wear or damage is observed, 

replace the part. 

•  If excessive wear or damage is observed on the 

sprocket inside sliding surface, replace the part. 

 

Gear 

•  Check whether the gear tooth surface is excessively 

worn or damaged, and there is evidence of burrs, 

chipping, wear, or damage on the gear spline. 

•  Remove minor flaws or scratches with oil stone. If 

excessive wear or damage is observed, replace the 

part. 

 

 

2-4 and Neutral Switch 

•  Check the continuity of 2-4 and Neutral switch. 
 

If defects are observed, replace the 4H and 4L switch.

 

 
 
 

221R300001

261R300003

 

Switch  
Stroke 

2-4 Switch 

Signal 

Neutral Switch  

Signal 

 

Terminal 

1 to 2 

Terminal 

1 to2 

1 Open  Close 

2 Close  Open 

 
 

7D-28  TRANSFER CASE 

Oil Pump 

•  Remove foreign materials from the strainer. If the 

strainer is damaged, replace it. 

If the area into which the shaft is inserted is excessively 
worn or damaged, replace the oil pump assembly. 
 

Clutch Hub Spline Play 

•  Set a dial indicator to the clutch hub to be measured.
•  Move the clutch hub as far as possible to both the 

right and the left. 

 

Note the dial indicator reading. 

•  If the measured value exceeds the specified limit, the 

clutch hub must be replaced. 

Clutch hub spline play 

Standard: 0-0.1 mm (0-0.004 in) 

Limit: 0.2 mm (0.008 in) 

 

226RS042

Bearings 

1.  Inspect the condition of all the needles and ball 

bearings. Wash bearings thoroughly in a cleaning 

solvent. Apply compressed air to the bearings. 

NOTE:  Do not allow the bearings to spin. Turn them 
slowly by hand. Spinning bearings may damage the 
rollers. 
2.  Lubricate the bearings with a light oil and check them 

for roughness by slowly turning the race by hand. 

 

 

Ball Bearing Play 

1.  Use a dial indicator to measure the ball bearing play.

2.  If the measured value exceeds the specified limit, the 

ball bearing must be replaced. 

Limit: 0.2 mm (0.008 in) 

 

226R3043

 

Synchronizers 

The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally 
assembled. 

Clean synchronizer components with clean solvent and 
air dry. 

Inspect the components for the following: 
•  Teeth for wear, scuffs, nicks, burrs or breaks. 
•  Keys and springs for wear, cracks or distortion, 

replace if these conditions are present. 

•  If scuffed, nicked or burred conditions cannot be 

corrected with a soft stone or crocus cloth, replace the 

component. 

 

TRANSFER CASE  7D-29 

Block Ring and Insert Clearance 

1.  Use a vernier caliper to measure the clearance 

between the block ring and the insert. 

2.  If the measured value exceeds the specified limit, the 

block ring and the insert must be replaced. 

Block ring and insert clearance 

Standard: 2.46-2.74 mm (0.097-0.108 in) 

Limit: 3.0 mm (0.118 in) 

226RS037

 

2WD-4WD Synchronizer (3-Cone) 

1.  Use a thickness gauge to measure the clearance 

between the block ring and the dog teeth. 

2.  If the measured value exceeds the specified limit, the 

2WD-4WD synchronizer assembly must be replaced.

Block ring and dog teeth clearance 

Standard: 1.5 mm (0.059 in) 

Limit: 0.8 mm (0.031 in) 

 

 

226R300019

 

Clutch Hub and Insert Clearance 

1.  Clutch Hub and Insert Clearance 

2.  Use a thickness gauge to measure the clearance 

between the clutch hub and the insert. 

3.  If the measured value exceeds the specified limit, the 

clutch hub and the insert must be replaced. 

Clutch hub and insert clearance 

Standard: 0.01-0.19 mm (0.0004-0.0075 in) 

Limit: 0.3 mm (0.012 in) 

 

226RS038

 

Detent Springs 

1.  Inspect the springs for distortion, cracks or wear. 

Replace if these conditions are present.