Isuzu KB P190. Manual - part 146

4C2-6  SHIFT ON THE FLY SYSTEM 

 

    

 

412RS045

14.Needle Bearing 

 

Remove needle bearing from inner shaft by using a special

tool. 

 

Remover 

 

: 5-8840-0027-0  

 

Sliding hammer 

: 5-8840-0084-0  

NOTE: 

Be careful not to damage the shaft. 

 

 

15.Oil Seal 

 

Remove oil seal from front axle case. 

NOTE: 

Be careful not to damage the front axle case. 

 

Inspection and Repair 

Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace. 

 

Visual Check 

•  Check and see if the inner shaft has such 

abnormalities as wear and damage. 

 

    

  

 

412RW014

 

 

 

   

 

412RS008

 

•  When inspecting the inner shaft, be sure to check and 

see if its splined part is twisted, worn, or cracked. If so, 
replace with a new shaft. In case such an abnormality 
in its gear part (a slide with sleeve), replace the shaft. 

 

SHIFT ON THE FLY SYSTEM  4C2-7 

 

    

    

    

  

 

412RS026

Inner Shaft Run-Out 

With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge. 

Inner Shaft Run-Out (Limit) 

mm (in) 

0.5 (0.02) 

NOTE: 
Do not heat the shaft to correct its bend. 

 

 

   

 

RTW440SH000101

 

Inner Shaft Bearing 

Inspect the state of inner shaft bearing. If any abnormality
such as smooth less is found, replace with a new inner 
shaft bearing. 

Insert a clutch gear and check the state of needle bearing.

If there is an abnormality such as smooth less, replace the
needle bearing. 

 

 

Sleeve 

Visual Check 

Check and see that there is not wear, damage, or checking 
in the sleeve. 

NOTE: 

Close inspection of the groove and inner gear are required

because those are important parts. 
 

 

    

    

 

412RW011

 

Functional Check 

Operate the sleeve with the inner shaft combined with the
clutch gear. 

If smooth less is felt, replace the sleeve. 

NOTE: 

Gear oil should be applied to the contact surface of gear.

 

 

   

 

412RW022

 

Dimensional Check 

Check the width of sleeve center groove. 

Sleeve Center Groove (Limit) 

mm (in) 

7.1 (0.28) 

4C2-8  SHIFT ON THE FLY SYSTEM 

 

   

 

RTW440SH000201

 

Clutch Gear 

Visual Check 

Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear. 

Functional Check 

If there is an abnormality such as smooth less when
operated in combination with sleeve, replace the clutch 
gear. 

NOTE: 

When inspection, gear oil should be applied to the contact
surface of gear. 

 

 

   

 

RTW440SH000301

Dimensional Check 

Make sure of the size illustrated. 

Clutch Gear Out Side Diameter (Limit) 

mm (in) 

36.98 (1.46) 

 

 

  

 

RTW440SH000501

 

   

 

RTW440SH000401

 

Actuator 

Visual Check 

Check and see that there is no damage, cracking, or other
abnormality. 

Functional Check 

Make sure of function with voltage (12V) applied to 
terminal 

3

, 

4

 and set the tester to terminal 

1

, 

2

 in 

accordance with the table below. 

 

State Port 

3

Port 

4

Port 

1

, 

2 

 

Conducting 

Function

A 

+ 

−−−− 

 C 

B 

−−−− 

+ 

× D 

If there is an abnormality, replace the actuator as an 
assembly. 

NOTE: 

Be careful not to permit the entry of water or dust into the ports 
of the actuator. 
Do not open the actuator cover, if the actuator will be reused. 

SHIFT ON THE FLY SYSTEM  4C2-9 

 

  

 

RTW440SH000601

 

 

 

    

  

 

RTW440SH000801

Dimension Check 

Measure illustration sized A, B, and C 

Limit mm 

(in) 

 

A 64.3 

(2.53) 

B 6.7 

(0.26) 

C 6.7 

(0.26) 

 

    

    

    

 

RTW440SH000701

 
 
 
 

Reassembly 

15. Oil seal 

Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer. 

Installer  

5-8840-2407-0  

Grip  

5-8840-0007-0  

 

    

    

    

    

    

   

 

412RS051

 
 
 
 

14. Needle  Bearing 

Force a new needle bearing into inner shaft by using a
special tool. 

Installer  

: 5-8840-2408-0  

Grip  

: 5-8840-0007-0