Transfer Assembly: Reassembly

Special Tools Required

Driver, 40 mm I.D. 07746-0030100
Attachment, 35 mm I.D. 07746-0030400
Driver 07749-0010000
Oil seal driver attachment 07JAD-PH80101
Companion flange holder 07RAB-TB4010A or 07RAB-TB4010B
Holder handle 07JAB-001020A
Attachment, 62 x 68 mm 07746-0010500

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 drive gear and the transfer output shaft as a set if either part is replaced.

Select the 35 mm thrust shim if the transfer output shaft is replaced. Calculate the thickness of the 35 mm thrust shim using the formula, and select the shim from the table.

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

Fig 1: Identifying Thrust Shim

Courtesy of AMERICAN HONDA MOTOR CO., INC.

THRUST SHIM, 35 mm

Shim No.	Part Number	Thickness
A	41361-PS3-000	0.72 mm (0.028 in.)
B	41362-PS3-000	0.75 mm (0.030 in.)
C	41363-PS3-000	0.78 mm (0.031 in.)
D	41364-PS3-000	0.81 mm (0.032 in.)
E	41365-PS3-000	0.84 mm (0.033 in.)
F	41366-PS3-000	0.87 mm (0.034 in.)
G	41367-PS3-000	0.90 mm (0.035 in.)
H	41368-PS3-000	0.93 mm (0.037 in.)
I	41369-PS3-000	0.96 mm (0.038 in.)
J	41370-PS3-000	0.99 mm (0.039 in.)
K	41371-PS3-000	1.02 mm (0.040 in.)
L	41372-PS3-000	1.05 mm (0.041 in.)
M	41373-PS3-000	1.08 mm (0.043 in.)
N	41374-PS3-000	1.11 mm (0.044 in.)

Select the 35 mm thrust shim if the tapered roller bearing on the transfer output shaft 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 table.
Install the 35 mm thrust shim (A) on the transfer output shaft (B), then install the tapered roller bearing (C) with the special tools and a press.

Fig 2: Installing Thrust Shim On Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the tapered roller bearing (A) on the bearing outer race of the companion flange side of the transfer housing.

Fig 3: Placing Tapered Roller Bearing On Bearing Outer Race
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the new oil seal (B) on the transfer housing with the special tools and a press.
Install the transfer output shaft (A) in the transfer housing (B). Do not install the 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), and locknut (C) on the transfer output shaft (D). Do not install the O-ring and back-up ring.

Fig 5: Installing Companion Flange, Conical Spring Washer, And Locknut On Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 6: Securing Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the special tool on the companion flange.
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.
Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (C), transfer collar (D), 25 mm thrust shim (E), tapered roller bearing (F), conical spring washer (G), and locknut (H).

Fig 7: Installing Transfer Shaft In Transfer Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.

Fig 8: Securing Hex Wrench In Bench Vise
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the locknut 118 N.m (12.0 kgf.m, 86.8 lbf.ft). Do not stake the locknut in this step.
Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
Temporarily install the transfer holder (A) and dowel pin (B) without O-ring, and tighten the bolts.
2003-2004 models:

Fig 9: Installing Transfer Holder And Dowel Pin And Torque Specifications(2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 10: Installing Transfer Holder And Dowel Pin And Torque Specifications(2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 companion flange (B).

Fig 11: Measuring Transfer Gear Backlash
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the transfer gear backlash.
Standard: 0.06-0.16 mm (0.02-0.06 in.)
Remove the transfer holder, and check the transfer drive gear tooth contact pattern.

Fig 12: Identifying Transfer Drive Gear Tooth Contact Pattern
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the backlash measurement is out of 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.

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 of each thrust shim to adjust the tooth contact.

Toe Contact
Use a thicker 35 mm thrust shim to move the transfer output shaft toward the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear away from the transfer output shaft to adjust the transfer gear backlash as follows:
- Increase the thickness of the 25 mm thrust shim.
- Reduce the thickness of the 68 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 away from the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear toward the transfer output shaft to adjust the transfer gear backlash as follows:
- Reduce the thickness of the 25 mm thrust shim.
- Increase the thickness of the 68 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 toward the transfer output shaft. 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 away from the transfer output shaft. 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

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 holder (A) from the transfer housing (B) after adjusting the transfer gear backlash or transfer gear tooth contact.
2003-2004 models:

Fig 13: Removing Transfer Holder From Transfer Housing (2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 14: Removing Transfer Holder From Transfer Housing (2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 15: Securing Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the special tool on the companion flange, then loosen the locknut.
Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (D).

Fig 16: Removing Locknut, Conical Spring Washer, And Companion Flange From Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (A) from the transfer housing (B).

Fig 17: Removing Transfer Output Shaft From Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the new transfer spacer (C) on the transfer output shaft in the direction shown, and install them in the transfer housing.
Coat the threads of the locknut and transfer output shaft with ATF.
Install the companion flange (A), new O-ring (B), back-up ring (C), new conical spring washer (D), and new locknut (E) on the transfer output shaft (F). Install the conical spring washer in the direction shown.

Fig 18: Installing Companion Flange, O-Ring, Back-Up Ring, Conical Spring Washer, And Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 19: Tightening Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the special tool on the companion flange.
Tighten the locknut while measuring the starting torque of the transfer output shaft.
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 turns 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.
Remove the special tool.
Stake the locknut into the transfer output shaft in depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).

Fig 20: Staking Locknut Into Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts.
2003-2004 models:

Fig 21: Installing Transfer Holder And Dowel Pin With Specified Torques(2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 22: Installing Transfer Holder And Dowel Pin With Specified Torques(2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 23: Measuring Starting Torque At Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotate the companion flange several times to seat the tapered roller bearings.
Measure the starting torque at the companion flange (C) using a torque wrench (D).
Standard

2003-2004 models:

2.16-3.57 N.m (22.0-36.4 kgf.cm, 19.1-31.6 lbf.in.)

2005-2006 models:

2.75-4.22 N.m (28.1-43.1 kgf.cm, 24.5-37.4 lbf.in.)
Remove the transfer holder from the transfer housing.
If the measurement is within the standard, go to step 53.
If the measurement is out of standard, put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.

Fig 24: Loosening Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Loosen the locknut.
Remove the locknut (A) and conical spring washer (B).

Fig 25: Removing Tapered Roller Bearing, Thrust Shim, Transfer Collar, Transfer Drive Gear, And Transfer Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the tapered roller bearing (C), 25 mm thrust shim (D), transfer collar (E), transfer drive gear (F), and transfer shaft (G) from the transfer holder (H).
Remove the tapered roller bearing outer race (A) and the 68 mm thrust shim (B) from the transfer holder (C).

Fig 26: Removing Tapered Roller Bearing Outer Race
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Measure the thickness of the 68 mm thrust shim, and select the new 68 mm thrust shim.

THRUST SHIM, 68 mm

Shim No.	Part Number	Thickness
ZV	23974-P1C-020	1.41 mm (0.056 in.)
ZW	23975-P1C-020	1.44 mm (0.057 in.)
ZX	23976-P1C-020	1.47 mm (0.058 in.)
ZY	23977-P1C-020	1.50 mm (0.060 in.)
ZZ	23978-P1C-020	1.53 mm (0.060 in.)
A	23941-PW5-000	1.56 mm (0.061 in.)
B	23942-PW5-000	1.59 mm (0.063 in.)
C	23943-PW5-000	1.62 mm (0.064 in.)
D	23944-PW5-000	1.65 mm (0.065 in.)
E	23945-PW5-000	1.68 mm (0.066 in.)
F	23946-PW5-000	1.71 mm (0.067 in.)
G	23947-PW5-000	1.74 mm (0.069 in.)
H	23948-PW5-000	1.77 mm (0.070 in.)
1	23949-PW5-000	1.80 mm (0.071 in.)
J	23950-PW5-000	1.83 mm (0.072 in.)
K	23951-PW5-000	1.86 mm (0.073 in.)
L	23952-PW5-000	1.89 mm (0.074 in.)
M	23953-PW5-000	1.92 mm (0.076 in.)
N	23954-PW5-000	1.95 mm (0.077 in.)
O	23955-PW5-000	1.98 mm (0.078 in.)
P	23956-PW5-000	2.01 mm (0.079 in.)
Q	23957-PW5-000	2.04 mm (0.080 in.)
R	23958-PW5-000	2.07 mm (0.081 in.)
S	23959-PW5-000	2.10 mm (0.083 in.)
T	23960-PW5-000	2.13 mm (0.084 in.)
U	23961-PW5-000	2.16 mm (0.085 in.)
V	23962-PW5-000	2.19 mm (0.086 in.)
W	23963-PW5-000	2.22 mm (0.087 in.)
X	23964-PW5-000	2.25 mm (0.089 in.)
Y	23965-PW5-000	2.28 mm (0.090 in.)
Z	23966-PW5-000	2.31 mm (0.091 in.)
AA	23967-PW5-000	2.34 mm (0.092 in.)
AB	23968-PW5-000	2.37 mm (0.093 in.)
AC	23969-PW5-000	2.40 mm (0.094 in.)
AD	23970-PW5-000	2.43 mm (0.096 in.)
AZ	23941-PW8-000	2.46 mm (0.097 in.)
BZ	23942-PW8-000	2.49 mm (0.098 in.)
CZ	23943-PW8-000	2.52 mm (0.099 in.)
DZ	23944-PW8-000	2.55 mm (0.100 in.)
EZ	23945-PW8-000	2.58 mm (0.102 in.)

Install the new 68 mm thrust shim (A) in the transfer holder, then install the tapered roller bearing outer race (B) with the special tools.

Fig 27: Installing Thrust Shim In Transfer Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (C), transfer collar (D), 25 mm thrust shim (E), tapered roller bearing (F), conical spring washer (G), and locknut (H). Install the conical spring washer in the direction shown.

Fig 28: Installing Transfer Shaft In Transfer Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.

Fig 29: Securing Hex Wrench In Bench Vise
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the locknut 118 N.m (12.0 kgf.m, 86.8 lbf.ft). Do not stake the locknut in this step.
Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts.
2003-2004 models:

Fig 30: Installing Transfer Holder And Dowel Pin With Specified Torques(2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 31: Installing Transfer Holder And Dowel Pin With Specified Torques(2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotate the companion flange several turns to seat the tapered roller bearings, and recheck the starting torque. Remove the transfer holder after adjusting the starting torque.
Stake the locknut into the transfer shaft in depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).

Fig 32: Staking Locknut Into Transfer Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the new O-ring (A) on the transfer holder (B), then install the transfer holder with the dowel pin (C) on the transfer housing (D).
2003-2004 models:

Fig 33: Installing O-Ring On Transfer Holder And Torque Specifications (2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 34: Installing O-Ring On Transfer Holder And Torque Specifications(2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.