Transfer Assembly: Reassembly

Special Tools Required

Driver handle, 40 mm I D 07746-0030100
Driver handle, 15 x 135L 07749-0010000
Attachment, 65 mm 07JAD-SH30100
Companion flange holder 07XAB-0010101
Attachment, 78 x 80 mm 07NAD-PX40100

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 transfer fluid (hypoid gear oil) during reassembly
Replace the tapered roller bearing and the tapered roller 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
To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise

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 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 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

EXAMPLE

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

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

C Existing 40 mm thrust shim thickness = 1 05 mm

X Replacement 40 mm thrust shim thickness

X = A/100-B/100 + C

= 2/100 - (-D/100 + 1

05 = 0 02 + 0 01 + 1 05 = 1 08 (mm)

Select No M 40 mm thrust shim of 1 08 mm (0 043 in)

Fig 1: Identifying Transfer Output Shaft

Courtesy of AMERICAN HONDA MOTOR CO., INC.

THRUST SHIM, 40 mm

THRUST SHIM 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) using the 40 mm driver handle and a press

Fig 2: Installing Thrust Shim On Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the tapered roller bearing (A) on the tapered roller bearing outer race of the companion flange side of the transfer housing, and install a new oil seal(B)

Fig 3: Identifying Tapered Roller Bearing And Oil Seal
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive the oil seal securely in the transfer housing using the driver handle and the 65 mm attachment

Fig 4: Pressing Oil Seal
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer output shaft (hypoid gear) (A) in the transfer housing (B) Do not install the transfer spacer and the thrust washer on the transfer output shaft (hypoid gear)

Fig 5: Identifying Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange (A), the conical spring washer (B) (in the direction shown), 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 6: Identifying Companion Flange And Conical Spring Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws

Fig 7: Measuring Starting Torque Of Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange holder on the companion flange
Tighten the locknut 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) Do not stake the locknut in this step
Remove the companion flange holder
Apply Prussian Blue to both sides of the transfer hypoid drive gear teeth lightly and evenly
Install the tapered roller bearing (A), the 25 mm thrust shim (B), and the transfer drive gear-shaft assembly (C) in the transfer housing (D)

Fig 8: Identifying Transfer Drive Gear-Shaft Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer cover (E), and secure it with the bolts Do not install the O-ring on the transfer cover
Rotate the companion flange in both directions until the transfer gears rotate one full turn in both directions
Set a dial indicator (A) on the transfer companion flange (B), position the dial indicator tip (C) on the top of the bolt (D)

Fig 9: Measuring Transfer Gear Backlash
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure transfer gear backlash
Standard 0 06-0 16 mm (0.002-0 006 in)
Remove the transfer cover and the transfer hypoid drive gear/shaft assembly, and check the transfer hypoid drive gear tooth contact pattern

Fig 10: Correct And Incorrect Tooth Contact Pattern
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the backlash measurement is out of standard, adjust the backlash with the 40 mm thrust shim, and recheck Do not use more than two 40 mm thrust shims to adjust the backlash

If the transfer gear tooth contact is incorrect, adjust the tooth contact with the 25 mm, 40 mm, or 80 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 the 25 mm thrust shim was reduced
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 the 25 mm thrust shim was reduced
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

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

Fig 11: Identifying Transfer Cover, Transfer Hypoid Drive Gear With Shaft Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws

Fig 12: Identifying Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange holder on the companion flange, then loosen the locknut
Remove the companion flange holder
Remove the locknut (A), the conical spring washer (B), and the companion flange (C) from the transfer output shaft (hypoid gear) (D)

Fig 13: Identifying Conical Spring Washer And Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (hypoid gear) from the transfer housing
Install a thrust washer (A) and a new transfer spacer (B) on the transfer output shaft (hypoid gear) (C), and install them in the transfer housing (D)

Fig 14: Identifying Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Coat the threads of the locknut and transfer output shaft (hypoid gear) with transfer fluid (hypoid gear oil)
Install the companion flange (A) Coat a new O-ring (B) with transfer fluid (hypoid gear oil), then install the O-ring, 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 15: Identifying Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws

Fig 16: Identifying Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange holder on the companion flange
Tighten the locknut 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 locknut 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 companion flange holder
Stake the locknut to a depth (A) of 0 7-1 2 mm (0 03-0 05 in) using a 3 5 mm punch (B)

Fig 17: Staking Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the tapered roller bearing (A), the 25 mm thrust shim (B), and the transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D)

Fig 18: Transfer Hypoid Drive Gear And Shaft Assembly With Torque Specification
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

Fig 19: Measuring Starting Torque Companion Flange Using Torque Wrench
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

2 74-4 64 N m

(28 0-47 4 kgf.cm, 24 3-41 1 lbf in)
Remove the transfer cover from the transfer housing
If the starting torque is within the standard, go to step 47
If the starting torque is out of standard, remove the bearing outer race (A) and the 80 mm thrust shim (B) from the transfer cover (C) If the tapered roller bearing outer race is press-fitted, remove the tapered roller bearing outer race by heating the transfer cover to about 212°F (100°C) using a heat gun (D) Do not heat the transfer cover more than 212°F(100°C)

Fig 20: Heating Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

THRUST SHIM, 80 mm

THRUST SHIM 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)
Al	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 thrust shim (A) and the tapered roller bearing outer race (B) in the transfer cover (C) If you heated the transfer cover, let it cool to room temperature before installing the 80 mm thrust shim

Fig 21: Identifying Thrust Shim And Tapered Roller Bearing Outer Race With Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive the tapered roller bearing outer race securely in the transfer cover using the driver handle and the 78 x 80 mm attachment so there is no clearance between the tapered roller bearing outer race, the 80 mm thrust shim, and the transfer cover

Fig 22: Identifying Tapered Roller Bearing Outer Race
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 specification
Install a new O-ring (A) on the transfer cover (B), then install the transfer cover on the transfer housing (C)

Fig 23: Transfer Cover And O-Ring With Torque Specification
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the filler plug (A), then refill the transfer assembly with transfer fluid (hypoid gear oil). Use an SAE 90 viscosity hypoid gear oil, API classified GL4 or GL5 only
Viscosity

SAE 90 Above 0°F (-18°C)

Hypoid Gear Oil Capacity. 0 45 L (0 48 US qt)

Fig 24: Filler Plug And Sealing Washer With Torque Specification
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the filler plug with a new sealing washer (B)