Transfer Assembly: Reassembly

Special Tools Required 

• Oil Seal Driver Attachment, 58 mm 07JAD-PH80101
• Companion Flange Holder 07RAB-TB4010A or 07RAB-TB4010B
• Holder Handle 07JAB-001020A
• Attachment, 72 x 75 mm 07746-0010600
• Driver Handle, 40 mm I.D. 07746-0030100
• Attachment, 35 mm I.D. 07746-0030400
• Driver Handle, 15 x 135L 07749-0010000

1. Select the 35 mm thrust shim if the transfer output shaft (hypoid gear) is replaced. Calculate the thickness of the 35 mm thrust shim using the following formula, and select the shim from the following table.

   FORMULA: A/100-B/100+C = X 

   A: Number on the existing transfer output shaft (hypoid gear) 

   B: Number on the replacement transfer output shaft (hypoid gear) 

   C: Thickness of the existing 35 mm thrust shim 

   X: Thickness needed for the replacement 35 mm thrust shim 

   NOTE: The number on the transfer output shaft is shown in 1/100 mm.

   Example 

   A: Existing transfer output shaft (hypoid gear) Number= +2 

   B: Replacement transfer output shaft (hypoid gear) Number= -1 

   C: Existing 35 mm thrust shim thickness = 1.05 mm 

   X: Replacement 35 mm thrust shim thickness 

   X = A/100-B/100 + C 

   = 2/100- (-1)/100 + 1.05 

   = 0.02 + 0.01 + 1.05 = 1.08 (mm) 

   Select No. M 35 mm thrust shim of 1.08 mm (0.043 in) 

   Fig 1: Identifying Transfer Output Shaft (Hypoid Gear) And Thrust Shim Thickness

   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   THRUST SHIM, 35 mm 

   THRUST SHIM THICKNESS SPECIFICATIONS
   
   

   Shim No.	Thickness
   A	0.72 mm (0.028 in)
   B	0.75 mm (0.030 in)
   C	0.78 mm (0.031 in)
   D	0.81 mm (0.032 in)
   E	0.84 mm (0.033 in)
   F	0.87 mm (0.034 in)
   G	0.90 mm (0.035 in)
   H	0.93 mm (0.037 in)
   I	0.96 mm (0.038 in)
   J	0.99 mm (0.039 in)
   K	1.02 mm (0.040 in)
   L	1.05 mm (0.041 in)
   M	1.08 mm (0.043 in)
   N	1.11 mm (0.044 in)

2. Select the 35 mm thrust shim if the tapered roller bearing on the transfer output shaft (hypoid gear) is replaced. Measure the thickness of the replacement bearing and the existing bearing, and calculate the difference of the bearing thickness. Adjust the thickness of the existing 35 mm thrust shim by the amount of the difference in bearing thickness, and select the replacement 35 mm thrust shim from the following table.
3. Install the 35 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) using the driver handle (40 mm I.D.), the attachment (35 mm I.D.), and a press.
   Fig 2: Pressing Thrust Shim On Transfer Output Shaft (Hypoid Gear)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Place the tapered roller bearing (A) on the tapered roller bearing outer race of the companion flange side of the transfer housing.
   Fig 3: Pressing Tapered Roller Bearing On Tapered Roller Bearing Outer Race Of Companion Flange Side Of Transfer Housing

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Install a new oil seal (B) on the transfer housing using the driver handle (15 x 135L) and the oil seal driver attachment (58 mm).
6. Install the transfer output shaft (hypoid gear) (A) in the transfer housing (B). Do not install the transfer spacer on the transfer output shaft (hypoid gear).
   Fig 4: Identifying Transfer Output Shaft (Hypoid Gear) In Transfer Housing

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Install the companion flange (A), the conical spring washer (B), and a new locknut (C) on the transfer output shaft (hypoid gear) (D). Do not install the O-ring and the back-up ring.
   Fig 5: Identifying Companion Flange, Conical Spring Washer And Locknut On Transfer Output Shaft (Hypoid Gear)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and a vise.
   Fig 6: Identifying Transfer Housing In Bench Vise

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Install the companion flange holder on the companion flange.
10. Tighten the locknut while measuring the starting torque so the starting torque is within 0.98-1.39 N.m (10.0-14.2 kgf.cm, 8.7-12.3 lbf.in). Do not stake the locknut in this step. Remove the companion flange holder.
11. Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (hypoid gear) (C), the transfer collar (D), the 25 mm thrust shim (E), the tapered roller bearing (F), the conical spring washer (G), and a new locknut (H).
    Fig 7: Identifying Transfer Shaft, Transfer Holder, Transfer Drive Gear (Hypoid Gear), Transfer Collar And Thrust Shim

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
12. Put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.
    Fig 8: Tightening Locknut And Transfer Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Tighten the locknut 118 N.m (12.0 kgf.m, 87 lbf.ft). Do not stake the locknut in this step.
14. Apply Prussian Blue to both sides of the transfer drive gear (hypoid gear) teeth lightly and evenly.
15. Temporarily install the transfer holder (A) and the dowel pin (B) without the O-ring, and tighten the bolts.
    Fig 9: Transfer Holder, Dowel Pin, O-Ring And Bolts With Torque Specification

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. Rotate the companion flange in both directions until the transfer gears rotate one full turn in both directions.
17. Set a dial indicator (A) on the companion flange (B).
    Fig 10: Setting Dial Indicator On Companion Flange

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. Measure the transfer gear backlash.

    Standard: 0.06-0.16 mm (0.002-0.006 in) 

19. Remove the transfer holder, and check the transfer drive gear (hypoid gear) tooth contact pattern.
    Fig 11: Identifying Transfer Drive Gear (Hypoid Gear) Tooth Contact Pattern

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
20. If the backlash measurement is out of the standard, adjust the backlash with the 35 mm thrust shim and recheck. Do not use more than two 35 mm thrust shims to adjust the backlash.
21. If the transfer gear tooth contact is incorrect, adjust the tooth contact with the 25 mm or 35 mm thrust shim. Do not use more than two shims of each thrust shim to adjust the tooth contact.
    • Toe Contact

      Use a thicker 35 mm thrust shim to move the transfer output shaft (hypoid gear) toward the transfer drive gear (hypoid gear). Because this movement causes the transfer gear backlash to change, move the transfer drive gear (hypoid gear) away from the transfer output shaft (hypoid gear) to adjust the transfer gear backlash as follows:

      • Increase the thickness of the 25 mm thrust shim.
      • Reduce the thickness of the 75 mm thrust shim by the amount you increased the 25 mm thrust shim.
    • Heel Contact

      Use a thinner 35 mm thrust shim to move the transfer output shaft (hypoid gear) away from the transfer drive gear (hypoid gear). Because this movement causes the transfer gear backlash to change, move the transfer drive gear (hypoid gear) toward the transfer output shaft (hypoid gear) to adjust the transfer gear backlash as follows:

      • Reduce the thickness of the 25 mm thrust shim.
      • Increase the thickness of the 75 mm thrust shim by amount you reduced the thickness of the 25 mm thrust shim.
    • Flank Contact

      Use a thinner thrust shim to move the transfer drive gear (hypoid gear) toward the transfer output shaft (hypoid gear). Flank contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Heel Contact.

    • Face Contact

      Use a thicker thrust shim to move the transfer drive gear (hypoid gear) away from the transfer output shaft (hypoid gear). Face contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Toe Contact.

      THRUST SHIM, 25 mm 

    THRUST SHIM THICKNESS SPECIFICATIONS
    
    

    Shim No.	Thickness
    1.70	1.70 mm (0.067 in)
    1.73	1.73 mm (0.068 in)
    1.76	1.76 mm (0.069 in)
    1.79	1.79 mm (0.070 in)
    1.82	1.82 mm (0.072 in)
    1.85	1.85 mm (0.073 in)
    1.88	1.88 mm (0.074 in)
    1.91	1.91 mm (0.075 in)
    1.94	1.94 mm (0.076 in)
    1.97	1.97 mm (0.078 in)
    2.00	2.00 mm (0.079 in)
    2.03	2.03 mm (0.080 in)
    2.06	2.06 mm (0.081 in)
    2.09	2.09 mm (0.082 in)
    2.12	2.12 mm (0.083 in)
    2.15	2.15 mm (0.085 in)
    2.18	2.18 mm (0.086 in)
    2.21	2.21 mm (0.087 in)
    2.24	2.24 mm (0.088 in)

22. Remove the transfer holder (A) from the transfer housing (B) after adjusting the transfer gear backlash or transfer gear tooth contact.
    Fig 12: Identifying Transfer Holder, Transfer Housing And Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials - between the transfer housing and the vise.
    Fig 13: Identifying Transfer Housing And Bench Vise

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
24. Install the companion flange holder on the companion flange, loosen the locknut, and remove the companion flange holder.
25. Remove the locknut (A), the conical spring washer (B), and the companion flange (C) from the transfer output shaft (hypoid gear) (D).
    Fig 14: Identifying Locknut, Conical Spring Washer, Companion Flange And Transfer Output Shaft (Hypoid Gear)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
26. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B).
    Fig 15: Identifying Transfer Output Shaft (Hypoid Gear) And Transfer Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
27. Install a new transfer spacer (C) on the transfer output shaft (hypoid gear) in the direction shown, and install them in the transfer housing.
28. Coat the threads of the locknut and the transfer output shaft with ATF.
29. Install the companion flange (A), a new O-ring (B), the back-up ring (C), a new conical spring washer (D), and a new locknut (E) on the transfer output shaft (hypoid gear) (F). Install the conical spring washer in the direction shown.
    Fig 16: Identifying Companion Flange, O-Ring, Back-Up Ring And Conical Spring Washer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
30. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
    Fig 17: Identifying Transfer Housing In Bench Vise

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
31. Install the companion flange holder on the companion flange.
32. Tighten the locknut while measuring the starting torque of the transfer output shaft (hypoid gear).

    Starting torque: 

    0.98-1.39 N.m (10.0-14.2 kgf.cm, 8.7-12.3 lbf.in) 

    Tightening torque: 

    132-260 N.m (13.5-26.5 kgf.m, 97.6-192 lbf.ft) 

    NOTE:

    • Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque.
    • If the starting torque exceeds 1.39 N.m (14.2 kgf.cm, 12.3 lbf.in), replace the transfer spacer and reassemble the parts. Do not adjust the starting torque with the locknut loose.
    • If the tightening torque exceeds 260 N.m (26.5 kgf.m, 192 lbf.ft), replace the transfer spacer and reassemble the parts.
33. Remove the companion flange holder.
34. Stake the locknut to a depth (A) of at least 0.7 mm (0.03 in) using a 3.5 mm punch (B).
    NOTE: Be careful not to make a crack on the locknut when staking.