Transfer Assembly: Reassembly
NOTE:
Transfer output shaft may also be referred to as transfer driven gear shaft.
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 driven gear (output) shaft as a set if either part is replaced.
- Select the 35-mm thrust shim if the transfer driven gear shaft is replaced. Calculate the thickness of the 35-mm thrust shim using the formula and select the correct shim from the table. See Fig 1 .
- 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 difference in bearing thickness, and select the replacement 35-mm thrust shim from thrust shim selection table. See Fig 1 .
- Install the 35-mm thrust shim on the transfer output shaft, then install the tapered roller bearing with the appropriate driver and a press. See TRANSFER OUTPUT SHAFT BEARING REPLACEMENT .
- 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 appropriate driver and a press.
- Install the transfer output shaft (driven gear) in the transfer housing. See Figure . Do not install the transfer spacer on the transfer output shaft.
- Install the companion flange, conical spring washer, and lock nut on the transfer output shaft. Do not install the "O" ring and back-up ring on the transfer output shaft.
- Secure the transfer housing in a bench vise with soft jaws, then install the holder on the companion flange. See Figure .
- Tighten the lock nut while measuring the starting torque so the starting torque is 10.2-15.1 INCH lbs. (1.15-1.71 N.m).
- Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
- Install the tapered roller bearing, 25-mm thrust shim, and transfer drive gear/shaft assembly in the transfer housing.
- Install the transfer cover, and tighten the bolts. See TORQUE SPECIFICATIONS . Do not install the "O" ring on the transfer cover.
- Rotate the companion flange several times to seat the tapered roller bearings.
- Set the dial indicator on the companion flange, then measure the transfer gear backlash. See Fig 2 . Standard is .02-.06" (.06-.16 mm).
- Remove the transfer cover, transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern.
- If the measurement of the backlash is out of the standard, adjust the transfer gear backlash with the 35-mm thrust shim and recheck. Do not use more than two 35-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 35-mm thrust shim. See Fig 3
. See GEAR TOOTH CONTACT PATTERN article in GENERAL INFORMATION. Do not use more than 2 shims 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 backlash to change, move the transfer drive gear away from the transfer output shaft to adjust the transfer gear backlash. Increase the thickness of the 25-mm thrust shim and reduce the thickness of the 75-mm thrust shim by the amount of increase thickness of the 25-mm thrust shim.
- Heel Contact - Use a thinner 35-mm thrust shim to move the transfer driven gear 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. Reduce the thickness of the 25-mm thrust shim and increase the thickness of the 75-mm thrust shim by amount of reduce thickness of the 25-mm thrust shim.
- Flank Contact - Use a thinner thrust shim to move the transfer output 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 output 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.
- Remove the transfer cover, transfer drive gear/shaft assembly, 25-mm thrust shim, and tapered roller bearing from the transfer housing after adjusting the transfer gear backlash or transfer gear tooth contact.
- Secure the transfer housing in a bench vise with soft jaws, then install the holder on the companion flange.
- Remove the lock nut, conical spring washer, and companion flange from the transfer output shaft.
- Remove the transfer output shaft from the transfer housing.
- Install the new transfer spacer on the transfer output shaft, and install them in the transfer housing.
- Coat the threads of the lock nut and transfer output shaft with ATF.
- Install the companion flange, new "O" ring, back-up ring, new conical spring washer, and new lock nut on the transfer output shaft. Install the conical spring washer. See Figure .
- Secure the transfer housing in a bench vise with soft jaws, then install the holder on the companion flange.
- Tighten the lock nut while measuring the starting torque of the transfer driven gear. Starting torque should be 10.2-15.1 INCH lbs. (1.15-1.71 N.m).
- Remove the companion flange holder.
- Stake the lock nut using a 3.5-mm punch.
- Install the tapered roller bearing, 25-mm thrust shim, and transfer drive gear/shaft assembly in the transfer housing.
- Temporarily install the transfer cover without the "O" ring and tighten the bolts.
- Secure the transfer housing in a bench vise with soft jaws, then rotate the companion flange several times to seat the tapered roller bearings. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
- Measure the total starting torque. See Fig 4 . Total starting torque is 13.4-15.8 INCH lbs. (1.51-1.78 N.m) plus transfer output starting torque value measured in step 26 .
- Remove the transfer cover.
- If the measurement is not within specification, remove the bearing outer race and 75-mm thrust shim from the transfer cover. 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. If the measurement is within the standard, go to step 36 .
- Measure the thickness of removed 75-mm thrust shim, and select the new 75-mm shim. Shims are available in thicknesses of .060-.105" (1.52-2.66 mm) in increments of .001" (.03 mm).
- Install the 75-mm thrust shim in the transfer cover. See Figure . If cover is heated, let it cool to room temperature before installing the thrust shim.
- Install the bearing outer race in the cover.
- After replacing the 75-mm thrust shim, recheck and ensure the total starting torque is within the specification.
- Install the new "O" ring on the transfer cover, then install the cover on the transfer housing.
NOTE:
To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
NOTE:
Do not stake the lock nut in following step.
NOTE:
To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
NOTE:
To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
NOTE:
Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque. If the starting torque exceeds 15.1 INCH lbs. (1.71 N.m), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the lock nut loose. If the tightening torque exceeds 217 ft. lbs. (294 N.m), replace the transfer spacer and reassemble the parts. Record the measurement of the starting torque, it is used to measure the total starting torque.
NOTE:
Do not heat the cover more than 212°F (100°C).