Transfer Assembly Reassembly

Special Tools Required
Driver 40 mm I.D. (  07746-0030100)
 

Driver attachment, 35 mm I.D. (  07746-0030400)
 
Handle driver (  07749-0010000)
 
Oil seal driver attachment (  07JAD-PH80101)
 
Companion flange holder (  07PAB-0020000)
 
Driver 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 driven gear as a set if either part is replaced.

1.Select the 35 mm thrust shim if the transfer driven gear is replaced. Calculate the thickness of the 35 mm thrust shim using the formula below, and select the shim from the table below.

NOTE: The number on the transfer driven gear is shown in 1/100 mm.

 

Example: 

THRUST SHIM, 35 mm
Shim No. Part Number Thickness 
41361-PS3-000 0.72 mm (0.028 in.) 
41362-PS3-000 0.75 mm (0.030 in.) 
41363-PS3-000 0.78 mm (0.031 in.) 
41364-PS3-000 0.81 mm (0.032 in.) 
41365-PS3-000 0.84 mm (0.033 in.) 
41366-PS3-000 0.87 mm (0.034 in.) 
41367-PS3-000 0.90 mm (0.035 in.) 
41368-PS3-000 0.93 mm (0.037 in.) 
41369-PS3-000 0.96 mm (0.038 in.) 
41370-PS3-000 0.99 mm (0.039 in.) 
41371-PS3-000 1.02 mm (0.040 in.) 
41372-PS3-000 1.05 mm (0.041 in.) 
41373-PS3-000 1.08 mm (0.043 in.) 
41374-PS3-000 1.11 mm (0.044 in.) 

2.Select the 35 mm thrust shim if the tapered roller bearing on the transfer driven 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 35 mm thrust shim by the amount of the difference in bearing thickness, and select the replacement 35 mm thrust shim from the above table.

3.Install the 35 mm thrust shim (A) on the transfer driven gear (B), then install the tapered roller bearing (C) with the special tools and a press.

 

4.Place the tapered roller bearing (A) on the bearing outer race of the companion flange side of the transfer housing.

 

5.Install the new oil seal (B) on the transfer housing with the special tools and a press.

6.Install the transfer driven gear (A) in the transfer housing (B). Do not install the transfer spacer on the transfer driven gear.

 

7.Install the companion flange (A), conical spring washer (B), and locknut (C) on the transfer driven gear (D). Do not install the O-ring and back-up ring.

 

8.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.

 

9.Install the special tool on the companion flange.

10.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.

11.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).

 

12.Put a 14 mm Allen wrench (A) in the transfer shaft (B), then secure the Allen wrench in a bench vise.

 

13.Tighten the locknut 118 N·m (12.0 kgf·m, 86.8 lbf·ft). Do not stake the locknut in this step.

14.Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.

15.Temporarily install the transfer holder (A) and dowel pin (B) without O-ring, and tighten the bolts.

 

16.Rotate the companion flange in both directions until the transfer gear rotate one full turn in both directions.

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

 

18.Measure the transfer gear backlash.

STANDARD: 0.06-0.16 mm (0.02-0.06 in.) 

19.Remove the transfer holder, and check the transfer drive gear tooth contact pattern.

 

20.If the measurement of the backlash is out of 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.

21.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 driven gear toward the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear away from the transfer driven gear 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 of increase of the 25 mm thrust shim.

  • Heel Contact
    Use a thinner 35 mm thrust shim to move the transfer driven 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 driven gear 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 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 driven 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 thrust shim to move the transfer drive gear away from the transfer driven 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
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.) 

22.Remove the transfer holder (A) from the transfer housing (B) after adjusting the transfer gear backlash or transfer gear tooth contact.

 

23.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.

 

24.Install the special tool on the companion flange, then loosen the locknut.

25. Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer driven gear (D).

 

26.Remove the transfer driven gear (A) from the transfer housing (B).

 

27.Install the new transfer spacer (C) on the transfer driven gear in the direction shown, and install them in the transfer housing.

28.Coat the threads of the locknut and transfer driven gear with ATF.

29.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 driven gear (F). Install the conical spring washer in the direction shown.

 

30.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.

 

31.Install the special tool on the companion flange.

32.Tighten the locknut while measuring the starting torque of the transfer driven gear.

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.

33.Remove the special tool.

34.Stake the locknut using a 3.5 mm punch.

 

35.Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts.

 

36.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 and the vise.

 

37.Rotate the companion flange several times to seat the tapered roller bearings.

38.Measure the staring torque at the companion flange (C) using a torque wrench (D).

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

39.Remove the transfer holder from the transfer housing.

40.If the measurement is within the standard, go to step 53.

41.If the measurement is out of standard, put a 14 mm Allen wrench (A) in the transfer shaft (B), then secure the Allen wrench in a bench vise.

 

42.Loosen the locknut.

43.Remove the locknut (A) and conical spring washer (B).

 

44.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).

45.Remove the tapered roller bearing outer race (A) and the 68 mm thrust shim (B) from the transfer holder (C).

 

46. 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.) 
23941-PW5-000 1.56 mm (0.061 in.) 
23942-PW5-000 1.59 mm (0.063 in.) 
23943-PW5-000 1.62 mm (0.064 in.) 
23944-PW5-000 1.65 mm (0.065 in.) 
23945-PW5-000 1.68 mm (0.066 in.) 
23946-PW5-000 1.71 mm (0.067 in.) 
23947-PW5-000 1.74 mm (0.069 in.) 
23948-PW5-000 1.77 mm (0.070 in.) 
23949-PW5-000 1.80 mm (0.071 in.) 
23950-PW5-000 1.83 mm (0.072 in.) 
23951-PW5-000 1.86 mm (0.073 in.) 
23952-PW5-000 1.89 mm (0.074 in.) 
23953-PW5-000 1.92 mm (0.076 in.) 
23954-PW5-000 1.95 mm (0.077 in.) 
23955-PW5-000 1.98 mm (0.078 in.) 
23956-PW5-000 2.01 mm (0.079 in.) 
23957-PW5-000 2.04 mm (0.080 in.) 
23958-PW5-000 2.07 mm (0.081 in.) 
23959-PW5-000 2.10 mm (0.083 in.) 
23960-PW5-000 2.13 mm (0.084 in.) 
23961-PW5-000 2.16 mm (0.085 in.) 
23962-PW5-000 2.19 mm (0.086 in.) 
23963-PW5-000 2.22 mm (0.087 in.) 
23964-PW5-000 2.25 mm (0.089 in.) 
23965-PW5-000 2.28 mm (0.090 in.) 
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.) 

47.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.

 

48.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.

 

49.Put a 14 mm Allen wrench (A) in the transfer shaft (B), then secure the Allen wrench in a bench vise.

 

50.Tighten the locknut 118 N·m (12.0 kgf·m, 86.8 lbf·ft). Do not stake the locknut in this step.

51.Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts.

 

52.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.

53.Stake the locknut of the transfer shaft using a 3.5 mm punch.

 

54.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).