Transfer Assembly

Transfer Assembly Disassembly

Special Tools Required
^ Companion flange holder 07XAB-0020100





1. Remove the transfer cover (A).
2. Remove the transfer drive gear/shaft assembly (B), 25 mm thrust shim (C), and tapered roller bearing (D).





3. Cut the lock tab on the locknut using a chisel.
4. Secure the transfer housing in a bench vise with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.





5. Install the special tool on the companion flange, then loosen the locknut.
6. Remove the special tool.





7. Remove the locknut (A), conical spring washer (B), back-up ring (C), O-ring (D), and companion flange (E) from the transfer output shaft (hypoid gear) (F).





8. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B), then remove the transfer spacer (C) from the transfer output shaft (hypoid gear).





9. Remove the oil seal (A) and tapered roller bearing (B) from the transfer housing (C).

Transfer Drive Gear Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 24 x 26 mm 07746-0010700
^ Attachment, 42 x 47 mm 07746-0010300

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





1. Remove the transfer shaft (A) from the transfer drive gear (B) with the special tools, bearing separator (C) and a press.





2. Install the new transfer drive gear (A) on the transfer shaft (B) with the special tools and a press.

Transfer Drive Gear Bearing Replacement

Special Tools Required
^ Driver 07749-0010000
^ Driver attachment 07947-6340500
^ Attachment, 62 x 68 mm 07746-0010500
^ Attachment, 45 x 55 mm 07MAD-PR90100





1. Remove the tapered roller bearing (A) from the transfer drive gear (B) with the special tools, bearing separator (C) and a press.





2. Install the new tapered roller bearing (A) on the transfer drive gear (B) with the special tools and a press.

Transfer Output Shaft (Hypoid Gear) Bearing Removal/Installation

Special Tools Required
^ Driver 40 mm I.D. 07746-0030100
^ Attachment, 35 mm I.D. 07746-0030400





1. Remove the tapered roller bearing (A) from the transfer output shaft (hypoid gear) (B) with a bearing separator (C) and a press. Place a shaft protector (D) between the transfer output shaft and a press to prevent damaging the shaft.
2. Install the 35 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B).





3. Install the tapered roller bearing (C) on the transfer output shaft (hypoid gear) (B) with the special tools and a press.

Transfer Housing Tapered Roller Bearing Outer Race Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 52 x 55 mm 07746-0010400
^ Oil seal driver attachment 07JAD-PH80101
^ Tapered bearing race installer A 07MAF-SP0011A
^ Installer shaft 07MAF-SP0013A

NOTE: Replace the bearing with a new one whenever the outer race is replaced.





1. Remove the bearing outer races from the transfer housing by heating the housing to about 212°F (100°C) with a heat gun. Do not heat the housing more than 212°F (100°C).

NOTE: Some bearing outer races (52 mm and 72 mm) are not press-fitted, and can be removed without heating the housing.





Bearing Outer Race Locations





2. Install the 52 mm bearing outer race (A) in the transfer housing (B) with the special tools.





3. Install the 72 mm (A) and 58 mm (B) bearing outer races in the transfer housing with the special tools.

Transfer Cover Tapered Roller Bearing Outer Race Removal/Installation

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 72 x 75 mm 07746-0010600

NOTE: Replace the bearing with a new one whenever the outer race is replaced.





1. 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).
2. Install the 75 mm thrust shim (A) in the transfer cover (B).





3. Install the bearing outer race (C) in the cover. If the outer race is press-fitted, use the special tools.

Reassembly

Special Tools Required
^ Driver 40 mm I.D. 07746-0030100
^ Attachment, 35 mm I.D. 07746-0030400
^ Driver 07749-0010000
^ Seal driver attachment 07GAD-PG40100 or 07GAD-PG40101
^ Companion flange holder 07XAB-0020100
^ Attachment, 72 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 a set if either part is replaced.
^ Replace the transfer drive gear and the transfer output shaft (hypoid gear) as a set if either part is replaced.











1. 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, and select the shim from the table.
2. 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 the 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.





3. 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.
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 output shaft (hypoid gear) (A) in the transfer housing (B). Do not install the transfer spacer on the transfer output shaft.





7. 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.
8. 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.





9. Tighten the locknut while measuring the starting torque so the starting torque is within 1.15 - 1.71 Nm (11.7 - 17.4 kgf-cm, 10.2 - 15.1 inch lbs.).

NOTE: Do not stake the locknut in this step.

TIGHTENING TORQUE: 108 - 294 Nm (11.0 - 30.0 kgf-cm, 79.6 - 217 ft. lbs.)
STARTING TORQUE: 1.15 - 1.71 Nm (11.7 - 17.4 kgf-cm, 10.2 - 15.1 inch lbs.)
10. Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
11. Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer drive gear/shaft assembly (C) in the transfer housing (D).





12. Install the transfer cover (E), and tighten the bolts.
Do not install the O-ring on the transfer cover.
13. Rotate the companion flange (A) several times to seat the tapered roller bearings.





14. Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt hole center (D).
15. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.02 - 0.06 inch)

















16. Remove the transfer cover, transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern.
17. 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.





18. 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 drive 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 thrust 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 thrust shim to move 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 Toe Contact.





19. 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.





20. 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 Loci the vise.





21. Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (hypoid gear) (D).
22. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B).





23. Install the new transfer spacer (C) on the transfer output shaft in the direction shown, and install them in the transfer housing.
24. Coat the threads of the locknut and transfer output shaft (hypoid gear) with ATF.





25. 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.





26. 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.
27. Tighten the locknut while measuring the starting torque of the transfer driven gear.
TIGHTENING TORQUE: 108 - 294 Nm (11.0 - 30.0 kgf-cm, 79.6 - 217 ft. lbs.)
STARTING TORQUE: 1.15 - 1.71 Nm (11.7 - 17.4 kgf-cm, 10.2 - 15.1 inch lbs.)

NOTE:
^ Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque.
^ If the starting torque exceeds 1.71 Nm (17.4 kgf-cm, 15.1 inch lbs.), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose.
^ If the tightening torque exceeds 294 Nm (30.0 kgf-cm, 217 ft. lbs.), 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.

28. Remove the special tools.





29. Stake the locknut using a 3.5 mm punch.
30. Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer drive gear/shaft assembly (C) in the transfer housing (D).





31. Temporarily install the transfer cover (E) without the O-ring, and tighten the bolts.
32. 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.





33. Measure the total starting torque. Total starting torque is the figure + the transfer driven gear starting torque measured in step 27.
TOTAL STARTING TORQUE = 1.51 - 1.78 Nm (15.4 - 18.1 kgf-cm, 13.4 - 15.7 inch lbs.) + Transfer Output Starting Torque Value (measured and written down in step 26)
34. Remove the transfer cover.





35. 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.





36. Measure the thickness of removed 75 mm thrust shim, and select the new 75 mm shim.
37. Install the 75 mm thrust shim (A) in the transfer cover (B). If you heated the cover, let it cool to room temperature before installing the thrust shim.





38. Install the bearing outer race (C) in the cover. Use the special tools to seat the bearing in the cover.
39. After replacing the 75 mm thrust shim, recheck and make sure the total starting torque is within the specification.





40. Install the new O-ring (A) on the transfer cover (B), then install the cover on the transfer housing (C).