Special Tools Required

Drive 40 mm I.D. 07746-0030100
Attachment, 35 mm I.D. 07746-0030400
Driver 07749-0010000.
Seat driver attachment 07GAD-PG40100 or 07GAD-PG40101
Companion flange holder 07XAB-0020100
Attachment, 75 x 75 mm 07746-0010600

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 set if either part is replaced.
Replace the transfer drive gear and the transfer output shaft (hypoid gear) as a set if either pat is replaced.

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

Fig 1: Shim Selection Formula (1 Of 2)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

Fig 2: Shim Selection Formula (2 Of 2)
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Select No. 35 mm thrust shim of 1.08 mm (0.043 in.).

Fig 3: Shim Selection Table
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Select the 35 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 existing 35 mm thrust shim by the amount of difference in bearing thickness, and select the replacement 35 mm thrust shim from the table on step 1.
Install the 35 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) with the special tools and a press.

Fig 4: Installing The 35 Mm Thrust Shim On The Transfer Output Shaft (Hypoid Gear) & Installing The Tapered Roller Bearing
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.
Install the new oil seal (B) in the transfer housing with the special tools and a press.

Fig 5: Installing The Oil Seal In The Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer output shaft (hypoid gear) (B). Do not install the transfer spacer on the transfer output shaft.

Fig 6: Installing The Transfer Output Shaft (Hypoid Gear)
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Install the companion flange (A), conical spring washer (B), and locknut (C) on the transfer output shaft (hypoid gear) (D). Do not install the O-ring and back-up ring on the transfer output shaft.

Fig 7: Installing The Companion Flange, Conical Spring Washer & Locknut On The 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, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
Tighten the locknut while measurement the starting torque so the starting torque is within 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 (lbf.in.).
NOTE: Do not stake the locknut in this step.

Tighten torque: 108-294 N.m (110-30.0 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.)

Fig 8: Tightening The Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply Prussian Blue to both sides of the transfer driver gear teeth lightly and evenly.
Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer driver gear/shaft assembly (C), in the transfer housing (D).
Install the transfer cover (E), and tighten the bolts Do not install the O-ring on the transfer cover.

Fig 9: Installing The Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotate the companion flange (A) several times to seat the tapered roller bearings.
Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt the hole center (D).

Fig 10: Setting A Dial Indicator On The Transfer 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.)
Remove the transfer cover, transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern.

Fig 11: Identifying Correct Tooth Contact Pattern
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 12: Identifying Incorrect Tooth Contact Pattern
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If the measurements 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 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. Do not use more than two 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 (hypoid gear) toward the transfer drive gear. Because this movement causes the transfer backlash to change, move the transfer dive 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 75 mm thrust shim by the amount of increase thickness of the 25 mm shim.
- Heel Contact
  Use a thinner 35 mm thrust shim to move the transfer output shaft (hypoid gear) 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 (hypoid gear) to adjust the transfer gear backlash as follows:
  - Reduce the thickness of the 25 mm thrust shim.
  - 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 drive gear toward 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 thicker shim to move the transfer drive gear away from the transfer drive gear away from 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 on Contact.
Fig 13: Shim Selection Chart
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer cover (A), transfer drive gear/shaft assembly (B), 25 mm thrust shim (C), and tapered roller bearing (D) from the transfer housing (E) after adjusting the transfer gear backlash or transfer gear tooth contact.

Fig 14: Removing The Transfer Cover, Transfer Drive Gear/Shaft Assembly, 25 Mm Thrust Shim & Tapered Roller Bearing From The Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent material between the transfer housing and the vise.

Fig 15: Installing The Special Tool On The Companion Flange
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Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (hypoid gear) (D).

Fig 16: Removing The Locknut, Conical Spring Washer & Companion Flange From The Transfer Output Shaft (Hypoid Gear)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B).
Install the new transfer spacer (C) on the transfer output shaft in the direction shown, and install them in the transfer housing.

Fig 17: Installing The Transfer Spacer On The Transfer Output Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Coat the threads of the locknut and transfer output shaft (hypoid gear) 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 (hypoid gear) (F). Install the conical spring washer in the direction shown.

Fig 18: Installing The Companion Flange, O-Ring, Back-Up Ring, Conical Spring Washer & Locknut On The 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, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 19: Installing The Special Tool On The Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the locknut while measuring the starting torque of the transfer driven gear.
Tighten 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 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.
- Write down the measurement of the starting torque: it is used to measure the total starting torque.
Remove the special tools.
Stake the locknut using a 3.5 mm punch.

Fig 20: Staking The Locknut
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Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer drive gear/shaft assembly (C) in the transfer housing (D).
Temporarily install the transfer cover (E) without the O-ring, and tighten the bolts.

Fig 21: Installing The Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) 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. Total starting torque is the figure below + the transfer driven gear starting torque measured in step 27 .
Total starting torque = 1.51-1.78 N.m (15.4-18.1 kgf.cm, 13.4-15.7 lbf.in.) + Transfer Output Starting Torque Value (measured and written down in step 26 )

Fig 22: Measuring The Total Starting Torque
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Remove the transfer cover.
If the measurement is out of standard, remove the bearing outer race (A) and 75 mm thrust shim (B) from the transfer cover (C). 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 (D). Do not heat the cover more than 212 °F (100 °C).
If the measurement is within the standard, go to step 37 .

Fig 23: Removing The Bearing Outer Race
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Measure the thickness of removed 75 mm thrust shim, and select the new 75 mm shim.

Fig 24: Thrust Shim Selection Table
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Install the 75 mm thrust shim (A) in the transfer recover (B). If you heated the cover, let it cool to room temperature before installing the thrust shim.
Install the bearing outer race (C) in the cover. use he special tools to seat the bearing in the cover.

Fig 25: Installing The Bearing Outer Race In The Cover
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After replacing the 75 mm thrust shim, recheck and make sure the total starting torque is within the specification.
Install the new O-ring (A) on the transfer cover (B), then install the cover on the transfer housing (C).

Fig 26: Installing The O-Ring On The Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.