Transfer Assembly Inspection

Set a dial indicator (A) on the companion flange (B).

Fig 1: Setting Dial Indicator On Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the transfer gear backlash.
Standard: 0.06-0.16 mm (0.02-0.06 in.)
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 2: Measuring Transfer Gear Backlash
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 (28.1-43.15 kgf.cm, 24.5-37.5 lbf.in.)
Remove the transfer assembly from the vise.
Remove the transfer holder (A) from the transfer housing (B), then remove the O-ring (C) from the transfer holder.
2003-2004 models:

Fig 3: Removing Transfer Holder From Transfer Housing And Torque Specifications(2003 - 2004 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2005-2006 models:

Fig 4: Removing Transfer Holder From Transfer Housing And Torque Specifications(2005 - 2006 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
Install the transfer holder, and tighten the bolts. Do not install the O-ring on the transfer holder.
Rotate the companion flange in both directions until the transfer gears rotate one full turn in both directions.
Remove the transfer holder, and check the transfer drive gear tooth contact pattern. The pattern should be centered on the gear teeth as shown.

Fig 5: Identifying Transfer Drive Gear Tooth Contact
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the measurements are out of standard or the tooth contact pattern are incorrect, disassemble the transfer assembly and repair it.