Transfer Assembly: Reassembly

Special Tools Required

Driver, 40 mm I.D. 07746-0030100
Attachment, 35 mm I.D. 07746-0030400
Driver 07749-0010000
Seal driver attachment 07GAD-PG40100 or 07GAD-PG40101
Companion flange holder 07XAB-0020100
Attachment, 72 x 75 mm 07746-0010600

NOTE:

While reassembling the transfer assembly:
- Check and adjust the transfer gear tooth contact.
- Measure and adjust the transfer gear backlash.
- Check and adjust the tapered roller bearing starting torque.
Coat all parts with ATF during reassembly.
Replace the tapered roller bearing and the bearing outer race as a set if either part is replaced.
Replace the transfer hypoid drive gear and the transfer output shaft (hypoid gear) as a set if either part is replaced.

Select the 40 mm thrust shim if the transfer output shaft (hypoid gear) is replaced. Calculate the thickness of the 40 mm thrust shim using the formula below, 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 40 mm thrust shim

X: Thickness needed for the replacement 40 mm thrust shim

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

Fig 1: Identifying Thrust Shim

Courtesy of AMERICAN HONDA MOTOR CO., INC.

THRUST SHIM, 40 mm

THICKNESS SPECIFICATIONS

Shim No.	Part Number	Thickness
A	29361-RDK-000	0.72 mm (0.028 in.)
B	29362-RDK-000	0.75 mm (0.030 in.)
C	29363-RDK-000	0.78 mm (0.031 in.)
D	29364-RDK-000	0.81 mm (0.032 in.)
E	29365-RDK-000	0.84 mm (0.033 in.)
F	29366-RDK-000	0.87 mm (0.034 in.)
G	29367-RDK-000	0.90 mm (0.035 in.)
H	29368-RDK-000	0.93 mm (0.037 in.)
I	29369-RDK-000	0.96 mm (0.038 in.)
J	29370-RDK-000	0.99 mm (0.039 in.)
K	29371-RDK-000	1.02 mm (0.040 in.)
L	29372-RDK-000	1.05 mm (0.041 in.)
M	29373-RDK-000	1.08 mm (0.043 in.)
N	29374-RDK-000	1.11 mm (0.044 in.)
O	29375-RDK-000	1.14 mm (0.045 in.)

Select the 40 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 40 mm thrust shim by the amount of difference in bearing thickness, and select the replacement 40 mm thrust shim.
Install the 40 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) with the special tool and a press.

Fig 2: Installing Tapered Roller Bearing With Special Tool And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the tapered roller bearing on the bearing outer race of the companion flange side of the transfer housing.
Install the new oil seal on the transfer housing with the special tools and a press.

Fig 3: Installing Oil Seal On Transfer Housing With Special Tools And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer output shaft (hypoid gear) (A) in the transfer housing (B). Do not install the thrust washers and transfer spacer on the transfer output shaft.

Fig 4: Installing Transfer Output Shaft In Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange (A), conical spring washer (B) in the direction shown, and lock nut (C) on the transfer output shaft (hypoid gear) (D). Do not install the O-ring and back up ring on the transfer output shaft.

Fig 5: Installing Companion Flange, Conical Spring Washer And Lock Nut On Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
Tighten the lock nut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.).
NOTE: Do not stake the lock nut in this step.

Starting Torque:

1.15-1.71 N.m

(11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.)

Fig 6: Securing Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply Prussian Blue to both side of the transfer hypoid drive gear teeth lightly and evenly.
Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D).

Fig 7: Installing Tapered Roller Bearing, Thrust Shim, And Transfer Hypoid Drive Gear/Shaft Assembly In Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer cover (E) and the bolts, and tighten the bolts. Do not install the O-ring on the transfer cover.
Rotate the companion flange several times to seat the tapered roller bearings.
Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt hole center (D).

Fig 8: Setting Dial Indicator On Transfer Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the transfer gear backlash.
Standard: 0.06-0.17 mm (0.002-0.007 in.)
Remove the transfer cover, transfer hypoid drive gear/shaft assembly, and check the transfer hypoid drive gear tooth contact pattern.

Fig 9: Checking Transfer Hypoid Drive Gear Tooth Contact Pattern
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the measurement of the backlash is out of the standard, adjust the transfer gear backlash with the 40 mm thrust shim and recheck. Do not use more than two 40 mm thrust shims to adjust the transfer gear backlash.

If the transfer gear tooth contact is incorrect, adjust the transfer gear tooth contact with the 25 mm or 40 mm thrust shim. Do not use more than two shims of each thrust shim to adjust the tooth contact.

Toe Contact
Use a thinner 40 mm thrust shim to move the transfer output shaft (hypoid gear) away from the transfer hypoid drive gear. Because this movement causes the transfer gear backlash to change, move the transfer hypoid drive 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 80 mm thrust shim by amount of reduce thickness of the 25 mm thrust shim.
Heel Contact
Use a thicker 40 mm thrust shim to move the transfer output shaft (hypoid gear) toward the transfer hypoid drive gear. Because this movement causes the transfer backlash to change, move the transfer hypoid drive 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 80 mm thrust shim by the amount of increase thickness of the 25 mm thrust shim.
Flank Contact
Use a thicker 25 mm thrust shim to move the transfer hypoid drive gear away from 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 thinner 25 mm thrust shim to move the transfer hypoid drive gear toward 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

THICKNESS SPECIFICATIONS

Shim No.	Part Number	Thickness
1.70	29411-P1C-000	1.70 mm (0.067 in.)
1.73	29412-P1C-000	1.73 mm (0.068 in.)
1.76	29413-P1C-000	1.76 mm (0.069 in.)
1.79	29414-P1C-000	1.79 mm (0.070 in.)
1.82	29415-P1C-000	1.82 mm (0.072 in.)
1.85	29416-P1C-000	1.85 mm (0.073 in.)
1.88	29417-P1C-000	1.88 mm (0.074 in.)
1.91	29418-P1C-000	1.91 mm (0.075 in.)
1.94	29419-P1C-000	1.94 mm (0.076 in.)
1.97	29420-P1C-000	1.97 mm (0.078 in.)
2.00	29421-P1C-000	2.00 mm (0.079 in.)
2.03	29422-P1C-000	2.03 mm (0.080 in.)
2.06	29423-P1C-000	2.06 mm (0.081 in.)
2.09	29424-P1C-000	2.09 mm (0.082 in.)
2.12	29425-P1C-000	2.12 mm (0.083 in.)
2.15	29426-P1C-000	2.15 mm (0.085 in.)
2.18	29427-P1C-000	2.18 mm (0.086 in.)
2.21	29428-P1C-000	2.21 mm (0.087 in.)
2.24	29429-P1C-000	2.24 mm (0.088 in.)

Remove the transfer cover (A), transfer hypoid drive gear/shaft assembly (B), 25 mm thrust shim (C), and tapered roller bearing (D) from the transfer housing (E) after adjusting the transfer gear backlash or transfer gear tooth contact.

Fig 10: Removing Transfer Cover, Transfer Hypoid Drive Gear/Shaft Assembly, Thrust Shim, And Tapered Roller Bearing From Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 11: Installing Special Tool On Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the lock nut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (hypoid gear) (D).

Fig 12: Removing Lock Nut, Conical Spring Washer, And Companion Flange From Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (hypoid gear) from the transfer housing.
Install the two thrust washers (A) and the new transfer spacer (B) on the transfer output shaft (hypoid gear) (C) in the direction shown, and install them in the transfer housing (D).

Fig 13: Installing Thrust Washers And Transfer Spacer On Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Coat the threads of the lock nut and transfer output shaft (hypoid gear) with ATF.
Install the companion flange (A), new O-ring (B), back up ring (C), new conical spring washer (D), and new lock nut (E) on the transfer output shaft (hypoid gear) (F). Install the conical spring washer in the direction shown.

Fig 14: Installing Companion Flange, O-Ring, Back-Up Ring, Conical Spring Washer, And Lock Nut On Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 15: Installing Special Tool On Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the lock nut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 1.15-1.71 N.m (11.7- 17.4 kgf.cm, 10.2-15.1 lbf.in.).
Tightening Torque:

108-294 N.m

(11.0-30.0 kgf.m, 79.6-217 lbf.ft)

Starting Torque:

1.15-1.71 N.m

(11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.)
NOTE:
- Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque.
- If the starting torque exceeds 1.71 N.m (17.4 kgf.cm, 15.1 lbf.in.), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the lock nut loose.
- If the tightening torque exceeds 294 N.m (30.0 kgf.m, 217 lbf.ft), replace the transfer spacer and reassemble the parts.
Remove the special tools.
Stake the lock nut in depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).

Fig 16: Staking Lock Nut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D).

Fig 17: Installing Tapered Roller Bearing, Thrust Shim, And Transfer Hypoid Drive Gear/Shaft Assembly In Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Temporally install the transfer cover (E) without the O-ring. Install and tighten the bolts.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 18: Installing Transfer Cover Without O-Ring
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotate the transfer companion flange (C) several times to seat the tapered roller bearings.
Measure the starting torque at the companion flange using a torque wrench (D) and a socket (E).
Total Starting Torque:

3.20-4.16 N.m

(32.6-42.4 kgf.cm, 28.3-36.8 lbf.in.)
Remove the transfer cover.
If the measurement is out of standard, remove the bearing outer race (A) and 80 mm thrust shim (B) from the transfer cover (C). If the bearing outer race is press-fitted, remove the bearing outer race by heating the cover to about 212 °F (100 °C) with a heat gun (D). Do not heat the cover more than 212°F(100°C).
If the measurement is within the standard, go to step 41.

Fig 19: Removing Bearing Outer Race By Heating Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Measure the thickness of removed 80 mm thrust shim, and select the new 80 mm shim.

THRUST SHIM, 80 mm

THICKNESS SPECIFICATIONS

Shim No.	Part Number	Thickness
A	41401-RDK-000	1.52 mm (0.060 in.)
B	41402-RDK-000	1.55 mm (0.061 in.)
C	41403-RDK-000	1.58 mm (0.062 in.)
D	41404-RDK-000	1.61 mm (0.063 in.)
E	41405-RDK-000	1.64 mm (0.065 in.)
F	41406-RDK-000	1.67 mm (0.066 in.)
G	41407-RDK-000	1.70 mm (0.067 in.)
H	41408-RDK-000	1.73 mm (0.068 in.)
I	41409-RDK-000	1.76 mm (0.069 in.)
J	41410-RDK-000	1.79 mm (0.070 in.)
K	41411-RDK-000	1.82 mm (0.072 in.)
L	41412-RDK-000	1.85 mm (0.073 in.)
M	41413-RDK-000	1.88 mm (0.074 in.)
N	41414-RDK-000	1.91 mm (0.075 in.)
O	41415-RDK-000	1.94 mm (0.076 in.)
P	41416-RDK-000	1.97 mm (0.078 in.)
Q	41417-RDK-000	2.00 mm (0.079 in.)
R	41418-RDK-000	2.03 mm (0.080 in.)
S	41419-RDK-000	2.06 mm (0.081 in.)
T	41420-RDK-000	2.09 mm (0.082 in.)
U	41421-RDK-000	2.12 mm (0.083 in.)
V	41422-RDK-000	2.15 mm (0.085 in.)
W	41423-RDK-000	2.18 mm (0.086 in.)
X	41424-RDK-000	2.21 mm (0.087 in.)
Y	41425-RDK-000	2.24 mm (0.088 in.)
Z	41426-RDK-000	2.27 mm (0.089 in.)
AA	41427-RDK-000	2.30 mm (0.091 in.)
AB	41428-RDK-000	2.33 mm (0.092 in.)
AC	41429-RDK-000	2.36 mm (0.093 in.)
AD	41430-RDK-000	2.39 mm (0.094 in.)
AE	41431-RDK-000	2.42 mm (0.095 in.)
AF	41432-RDK-000	2.45 mm (0.096 in.)
AG	41433-RDK-000	2.48 mm (0.098 in.)
AH	41434-RDK-000	2.51 mm (0.099 in.)
AI	41435-RDK-000	2.54 mm (0.100 in.)
AJ	41436-RDK-000	2.57 mm (0.101 in.)
AK	41437-RDK-000	2.60 mm (0.102 in.)
AL	41438-RDK-000	2.63 mm (0.104 in.)
AM	41439-RDK-000	2.66 mm (0.105 in.)

Install the 80 mm trust shim (A) and bearing outer race (B) in the transfer cover (C). If you heated the cover, let it cool to room temperature before installing the thrust shim.

Fig 20: Installing Trust Shim And Bearing Outer Race In Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive the outer race securely in the cover with the special tools so there is no clearance between the outer race, thrust shim, and cover.

Fig 21: Driving Outer Race In Cover With Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.
After replacing the 80 mm thrust shim, recheck and make sure that the total starting torque is within the specification.
Install the new O-ring (A) on the transfer cover (B), then install the cover on the transfer housing (C).

Fig 22: Installing Cover On Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the filler plug (A), then refill the transfer with transfer fluid (hypoid gear oil) into the filler hole. Use a SAE 90 or SAE 80W-90 viscosity hypoid gear oil, API classified GL4 or GL5 only.
Viscosity

SAE 90: Above 0°F (-18 °C)

SAE80W-90: Below 0 °F (-18 °C)

Hypoid Gear Oil Capacity: 0.45 L (0.48 US qt)

Fig 23: Installing Filler Plug With Sealing Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the filler plug with a new sealing washer (B).