Transfer Output Shaft
Transfer Output ShaftTransmission Housing Bearing Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 72 x 75 mm 07746-0010600
1. Remove the transfer output shaft bearing (A) from the transmission housing (B). If the bearing is press-fitted, remove the bearing by heating the housing to about 212°F (100°C) with a heat gun (C). Do not heat the housing more than 212°F (100°C).
2. Install the new bearing in the housing, use the special tools to seat the bearing in the housing.
3. Select the 24 mm thrust shim.
Transfer Output Shaft Bearing Replacement
Special Tools Required
^ Driver 40 mm I.D. 07746-0030100
^ Attachment, 35 mm I.D. 07746-0030400
1. Remove the transfer output shaft bearing (A) with a universal two-jaw puller (B) and a bearing separator (C). Place a shaft protector (D) between the transfer output shaft and a puller to prevent damaging the shaft.
2. Install the new bearing (A) on the transfer output shaft (B) with the special tools and a press.
3. Select the 24 mm thrust shim.
Thrust Clearance Inspection
NOTE: If the transfer output shaft, transmission housing, or torque converter housing is replaced, the output shaft thrust clearance must be adjusted with the 24 mm thrust shim.
1. Install the transfer output shaft in the torque converter housing.
2. Measure the distance (A) between the torque converter housing surface (B) and the 24 mm thrust shim mounting surface (C) of the transfer output shaft, then note the measurement (Measurement A).
3. Measure the distance (B) between the transmission housing surface (C) and the bearing inner race (D), then note the measurement (Measurement B). Do not push the bearing inner race while measuring the distance.
4. Calculate the thickness of the 24 mm thrust shim using the formula.
FORMULA:
Output Shaft Thrust Clearance including 24 mm Thrust Shim Thickness
= Measurement B-Measurement A
+Transmission Housing Gasket Thickness (0.5 ± 0.1 mm)
Output Shaft Thrust Clearance
STANDARD: 0 - 0.484 mm (0 - 0.019 inch)
Example:
Measurement A: 37.0 mm (1.475 inch)
Measurement B: 38.5 mm (1.516 inch)
24 mm Thrust Shim Thickness:
Thick = 38.5 - 37.0 + (0.5 + 0.1) + 0.01 - 0.484 = 1.626
Thin = 38.5 - 37.0 + (0.5 0.1) - 0.01 = 1.890
NOTE: The 24 mm thrust shim thickness allowance is 1.626 - 1.890 mm (0.064 - 0.074 inch) you can use the shims number A, B or C in this case.
5. Select the 24 mm thrust shim from the following table.
Inspection
NOTE: To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and a vise.
Transfer Gear Backlash Measurement
1. 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)
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.02 - 0.06 inch)
Total Starting Torque Measurement
3. Rotate the companion flange several time to seat the tapered roller bearings.
4. Measure the starting torque at the companion flange (A) using a torque wrench (B).
STANDARD: 2.65 - 4.75 Nm (27.0 - 48.5 kgf-cm, 23.5 - 42.0 inch lbs.)
Transfer Gear (Hypoid Gear) Tooth Contact Inspection
5. Remove the transfer cover (A) from the transfer housing (B), and remove the O-ring (C) from the transfer cover.
6. Remove the transfer drive gear/shaft assembly (D), 25 mm thrust shim (E), and tapered roller bearing (F).
7. Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
8. Install the tapered roller bearing, 25 mm thrust shim, and transfer drive gear/shaft assembly in the transfer housing.
9. Install the transfer cover, and tighten the bolts. Do not install the O-ring on the transfer cover.
10. Rotate the companion flange in both directions until the transfer gear rotates one full turn in both directions.
11. Remove the transfer cover and transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern. The pattern should be centered on the gear teeth as shown.
12. If the measurements are out of standard or the tooth pattern are not correct, disassemble the transfer assembly and repair it.