Automatic Transmission: Reassembly

Special Tools Required

Driver Handle, 40 mm I.D. 07746-0030100
Driver Handle, 15 x 135L 07749-0010000
Oil Seal Driver Attachment, 65 mm 07JAD-SH30100
Flange Holder 07XAB-0010101
Bearing Driver 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.
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 wood blocks or equivalent materials between the transfer housing and a bench 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 - (- 1)/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 Shafts And Thrust Shims

Courtesy of AMERICAN HONDA MOTOR CO., INC.

THRUST SHIM, 40 MM

No.	Thickness
A	0.72 mm (0.0283 in)
B	0.75 mm (0.0295 in)
C	0.78 mm (0.0307 in)
D	0.81 mm (0.0319 in)
E	0.84 mm (0.0331 in)
F	0.87 mm (0.0343 in)
G	0.90 mm (0.0354 in)
H	0.93 mm (0.0366 in)
I	0.96 mm (0.0378 in)
J	0.99 mm (0.0390 in)
K	1.02 mm (0.0402 in)
L	1.05 mm (0.0413 in)
M	1.08 mm (0.0425 in)
N	1.11 mm (0.0437 in)
O	1.14 mm (0.0449 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 I.D. driver handle and a press.

Fig 2: Installing Thrust Shim On Transfer Output Shaft Using Driver Handle And Press
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 in the transfer housing (B), and install a new oil seal (C).

Fig 3: Placing Tapered Roller Bearing On Tapered Roller Bearing Outer Race In Transfer Housing And Oil Seal
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive the oil seal securely in the transfer housing using the 15 x 135L driver handle and the 65 mm oil seal driver attachment.

Fig 4: Driving Oil Seal In Transfer Housing Using Driver Handle And Oil Seal Driver Attachment
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: Installing Transfer Output Shaft In Transfer Housing
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, Conical Spring Washer Locknut And Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with wood blocks.

Fig 7: Securing Transfer Housing In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 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 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: Tapered Roller Bearing, Thrust Shim And Transfer Drive Gear/Shaft Assembly With Torque Specifications
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: Setting Dial Indicator On Transfer Companion Flange, Position Dial Indicator Tip On Top Of Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure transfer gear backlash.
Standard: 0.06- 0.16 mm (0.0024- 0.0063 in)
Remove the transfer cover and the transfer hypoid drive gear/shaft assembly, and check the transfer hypoid drive gear tooth contact pattern.
CORRECT TOOTH CONTACT PATTERN

Fig 10: Checking Transfer Hypoid Drive Gear Tooth Contact Pattern (Correct Tooth Contact Pattern)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

INCORRECT TOOTH CONTACT PATTERN

Fig 11: Checking Transfer Hypoid Drive Gear Tooth Contact Pattern (Incorrect Tooth Contact Pattern)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the backlash is out of the 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 reducing the amount 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 reducing the amount 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

No.	Thickness
1.70	1.70 mm (0.0669 in)
1.73	1.73 mm (0.0681 in)
1.76	1.76 mm (0.0693 in)
1.79	1.79 mm (0.0705 in)
1.82	1.82 mm (0.0717 in)
1.85	1.85 mm (0.0728 in.)
1.88	1.88 mm (0.0740 in)
1.91	1.91 mm (0.0752 in)
1.94	1.94 mm (0.0764 in)
1.97	1.97 mm (0.0776 in)
2.00	2.00 mm (0.0787 in)
2.03	2.03 mm (0.0799 in)
2.06	2.06 mm (0.0811 in)
2.09	2.09 mm (0.0823 in)
2.12	2.12 mm (0.0835 in)
2.15	2.15 mm (0.0846 in)
2.18	2.18 mm (0.0858 in)
2.21	2.21 mm (0.0870 in)
2.24	2.24 mm (0.0882 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 12: Identifying Transfer Cover And Housing, Drive Gear/Shaft Assembly, Thrust Shim And Tapered Roller Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in the bench vise (B) with wood blocks.

Fig 13: Securing Transfer Housing In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the flange holder on the companion flange, then loosen the locknut.
Remove the 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 14: Identifying Locknut, Conical Spring Washer, Companion Flange, Transfer Housing And Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (hypoid gear) from the transfer housing (E).
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 15: Identifying Thrust Washer, Transfer Spacer, Transfer Output Shaft, And Transfer Housing
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 16: Identifying Companion Flange, Transfer Fluid, O-Ring, Back-Up Ring, Washer, Locknut And Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in the bench vise (B) with wood blocks.

Fig 17: Securing Transfer Housing In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the flange holder on the companion flange.
Tighten the locknut to the lower torque specification, then check starting torque. If starting torque is low, increase the torque on the locknut until the starting torque is acceptable.
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 flange holder.
Stake the locknut to a depth (A) of at least 0.7 mm (0.03 in) using a 3.5 mm punch (B). Be careful not to make a crack on the locknut when staking.

Fig 18: Staking Locknut To Depth At Least Using Punch
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 19: Tapered Roller Bearing, Thrust Shim, Drive Gear/Shaft Assembly, Transfer Housing And Cover With Torque Specifications
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 the bench vise (B) with wood blocks.

Fig 20: Securing Transfer Housing In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotate the transfer companion flange (C) several times to seat the tapered roller bearings.
Measure the total starting torque at the companion flange by using a torque wrench (D) and a socket (E).
Calculate the transfer hypoid drive gear/shaft starting torque by using the following formula.
Transfer Hypoid Drive Gear/Shaft Starting

Torque Formula:

A - B = X

A: Actual total starting torque (measured in step 39)

B: Actual transfer output shaft (hypoid gear) starting torque (measured in step 32)

X: Transfer hypoid drive gear-shaft starting torque
Check that the calculated transfer hypoid drive gear/shaft starting torque is within the following reference value range.
Reference Value Range of Transfer Hypoid Drive Gear/Shaft Starting Torque:

1.49 - 2.52 N.m (15.2 - 25.7 kgf.cm, 13.1 - 22.3 lbf.in)
- If the calculated transfer hypoid drive gear/shaft starting torque is within the reference value range, remove the transfer cover from the transfer housing, then go to step 48.
- If the calculated transfer hypoid drive gear/shaft starting torque is out of the reference value range, go to step 42.
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 21: Removing Tapered Roller Bearing Outer Race By Heating Transfer Cover Using Heat Gun
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

No.	Thickness
A	1.52 mm (0.0598 in)
B	1.55 mm (0.0610 in)
C	1.58 mm (0.0622 in)
D	1.61 mm (0.0634 in)
E	1.64 mm (0.0646 in)
F	1.67 mm (0.0657 in)
G	1.70 mm (0.0669 in)
H	1.73 mm (0.0681 in)
1	1.76 mm (0.0693 in)
J	1.79 mm (0.0705 in)
K	1.82 mm (0.0717 in)
L	1.85 mm (0.0728 in)
M	1.88 mm (0.0740 in)
N	1.91 mm (0.0752 in)
O	1.94 mm (0.0764 in)
P	1.97 mm (0.0776 in)
Q	2.00 mm (0.0787 in)
R	2.03 mm (0.0799 in)
S	2.06 mm (0.0811 in)
T	2.09 mm (0.0823 in)
U	2.12 mm (0.0835 in)
V	2.15 mm (0.0846 in)
W	2.18 mm (0.0858 in)
X	2.21 mm (0.0870 in)
Y	2.24 mm (0.0882 in)
Z	2.27 mm (0.0894 in)
AA	2.30 mm (0.0906 in)
AB	2.33 mm (0.0917 in)
AC	2.36 mm (0.0929 in)
AD	2.39 mm (0.0941 in)
AE	2.42 mm (0.0953 in)
AF	2.45 mm (0.0965 in)
AG	2.48 mm (0.0976 in.)
AH	2.51 mm (0.0988 in)
Al	2.54 mm (0.1000 in)
AJ	2.57 mm (0.1012 in)
AK	2.60 mm (0.1024 in)
AL	2.63 mm (0.1035 in)
AM	2.66 mm (0.1047 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 22: Identifying Thrust Shim And Tapered Roller Bearing Outer Race In Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive the 80 mm tapered roller bearing outer race securely in the transfer cover using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment so there is no clearance between the 80 mm tapered roller bearing outer race, the 80 mm thrust shim, and the transfer cover.

Fig 23: Driving Tapered Roller Bearing Outer Race Using Driver Handle And Bearing Driver Attachment
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the oil seal from the transfer cover (see TRANSFER COVER OIL SEAL REPLACEMENT ).
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 24: O-Ring, Transfer Cover And Transfer Housing With Torque Specifications
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 25: Filler Plug And Sealing Washer With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the filler plug with a new sealing washer (B).