Transfer Output Shaft, Disassemble & Service
Transfer Output Shaft Bearing ReplacementSpecial Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Remove the transfer output shaft bearing (A) with a commercially available puller (B), bearing separator (C), and shaft protector (D). Place a shaft protector between the transfer output shaft and a puller to prevent damaging the shaft.
2. Install the new bearing on the transfer output shaft with the driver (40 mm I.D.) and a press.
Oil Seal Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 65 mm 07JAD-SH30100
1. Remove the oil seal from the torque converter housing.
2. Install the new oil seal flush to the torque converter housing with the driver and attachment (65 mm).
Transmission 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) 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 in the direction shown.
3. Drive the new bearing until it bottoms in the housing with the driver and attachment (72 x 75 mm).
Transfer Output Shaft Installation Height Inspection/Adjustment
NOTE: If the transfer output shaft, transfer output shaft bearing, transfer output shaft transmission housing bearing, transmission housing, or torque converter housing were replaced, adjust the transfer output shaft installation height with the 28.5 mm thrust shim.
1. Install the transfer output shaft (A) in the torque converter housing, and install the 28.5 mm thrust shim (B) on the top of the shaft. If you replace the 28.5 mm thrust shim with a new one, use the same thickness shim as the old one.
Standard: 46.31-46.35 mm (1.823-1.825 in.)
2. Install a new gasket (C) on the torque converter housing.
3. Measure the height (D) of the transfer output shaft installation between the surface (E) of the gasket and the top (F) of the 28.5 mm thrust shim in at least three places. Use the average as the actual height.
4. If the measurement is out of standard, remove the 28.5 mm thrust shim and measure its thickness.
5. Select and install a new thrust shim, then recheck the installation height.
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 the dial indicator tip (C) on the direct extension of the bolt hole canter (D).
2. Measure the transfer gear backlash.
Standard: 0.06-0.17 mm (0.002-0.007 in.)
Total Starting Torque Measurement
3. Rotate the transfer companion flange several times to seat the tapered roller bearings.
4. Measure the staring torque at the companion flange (A) using a torque wrench (B) and a socket (C).
Standard: 3.20-4.16 N.m (32.6-42.4 kgf.cm, 28.3-36.8 lbf.in.)
5. If the measurements are out of standard, disassemble the transfer assembly and repair it.
Disassembly
Exploded View
Transfer Case:
Special Tools Required
Companion flange holder 07XAB-0020100
1. Remove the transfer cover (A) from the transfer housing (B).
2. Remove the transfer hypoid drive gear/shaft assembly (C), the 25 mm thrust shim (D), and the tapered roller bearing (E).
3. Remove the O-ring (F) from the cover.
4. Drain the transfer fluid (hypoid gear oil) from the transfer housing.
5. Cut the lock tab on the locknut using a chisel.
6. 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.
7. Install the companion flange holder on the companion flange, then loosen the locknut.
8. Remove the companion flange holder.
9. Remove the locknut (A), the conical spring washer (B), the back-up ring (C), the O-ring (D), and the companion flange (E) from the transfer output shaft (hypoid gear) (F).
10. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B), then remove the thrust washers (C) and the transfer spacer (D) from the transfer output shaft (hypoid gear).
11. Remove the oil seal (A) and the tapered roller bearing (B) from the transfer housing.
Transfer Hypoid Drive Gear Bearing Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 42 x 47 mm 07746-0010300
^ Attachment, 40 x 50 mm 07LAD-PW50601
1. Remove the tapered roller bearing (A) from the transfer hypoid drive gear (B) with the driver, attachment (42 x 47 mm), the bearing separator (C) and the press.
2. Install a new bearing on the transfer hypoid drive gear with the driver, attachment (42 x 47 mm), attachment (40 x 50 mm), and the press.
Transfer Output Shaft (Hypoid Gear) Bearing Removal/Installation
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
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 the press to prevent damaging the shaft.
2. Install the 40 mm thrust shim (A) over the transfer output shaft (hypoid gear).
3. Install the tapered roller bearing over the transfer output shaft (hypoid gear) with the driver (40 mm I.D.), and the 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 52 mm bearing outer race (A) and the 75 mm outer race (B) from the transfer housing (C).
NOTE: Some bearing outer races (52 mm and 75 mm) are press-fitted in the housing, and these races are removed by heating the housing.
2. Remove the 58 mm bearing outer race (A) from the transfer housing (B) by heating the housing to about 212°F (100 °C) with a heat gun (C). Remove the 52 mm and the 75 mm outer races by heating, if they are press-fitted. Do not heat the housing more than 212°F (100 °C).
3. Install the 52 mm bearing outer race (A) until it bottoms in the transfer housing with the driver and attachment (52 x 55 mm).
4. Install the 75 mm bearing outer race (A) and the 58 mm outer race (B) in the transfer housing (C), set the oil seal driver attachment and tapered bearing race installer A attachments over the races, and install the installer shaft through the attachments.
5. Tighten the installer shaft nut (D) to install the races (A) (B) into the transfer housing (C) securely.
Transfer Cover Tapered Roller Bearing Outer Race Removal/Installation
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 80 mm 07NAD-PX40100
NOTE: Replace the bearing with a new one whenever the outer race is replaced.
1. Remove the bearing outer race (A) and the 80 mm thrust shim (B) from the transfer cover (C). If the bearing outer race is press-fitted, remove the 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 80 mm trust shim (A) and the bearing outer race (B) in the transfer cover (C).
3. Drive the outer race securely in the cover with the driver and attachment (78 x 80 mm), so there is no clearance between the outer race, thrust shim, and cover.
Transfer Cover Oil Seal Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 65 mm 07JAD-SH30100
1. Remove the oil seal from the transfer cover.
2. Install the new oil seal (A) in the transfer cover (B) to a height (C) of 0-1 mm (0-0.04 in.) above the cover surface with the driver and attachment (65 mm).
Reassembly
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 35 mm I.D. 07746-0030400
^ Driver 07749-0010000
^ Oil seal driver attachment 07GAD-PG40100 or 07GAD-PG40101
^ Companion flange holder 07XAB-0020100
^ Attachment, 78 x 80 mm 07NAD-PX40100
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 hypoid drive gear and the transfer output shaft (hypoid gear) as a set if either part is replaced.
1. Select the 40 mm thrust shim if the transfer output shaft (hypoid gear) is replaced. Calculate the thickness of the 40 mm thrust shim using the formula below, and select the shim from the following table.
A: Number on the existing transfer output shaft (hypoid gear)
B: Number on the replacement transfer output shaft (hypoid gear)
C: Thickness of the existing 40 mm thrust shim
X: Thickness needed for the replacement 40 mm thrust shim
NOTE: The number on the transfer output shaft (hypoid gear) is shown in 1/100 mm.
2. Select the 40 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 40 mm thrust shim by the amount of difference in bearing thickness, and select the replacement 40 mm thrust shim.
3. Install the 40 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) with the driver (40 mm I.D.) and a press.
4. Place the tapered roller bearing on the bearing outer race of the companion flange side of the transfer housing.
5. Install a new oil seal on the transfer housing with the driver, oil seal driver attachment, and the press.
6. Install the transfer output shaft (hypoid gear) (A) in the transfer housing (B). Do not install the thrust washers and transfer spacer on the transfer output shaft.
7. Install the companion flange (A), the conical spring washer (B) in the direction shown, and the 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 companion flange holder 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 of the transfer output shaft (hypoid gear) so the starting torque is within 1.15-1.71 N.m (11.717.4 kgf.cm, 10.2-15.1 lbf.in.).
NOTE: Do not stake the locknut in this step.Apply Prussian Blue to both sides of the transfer hypoid drive gear teeth lightly and evenly.
10. Install the tapered roller bearing (A), the 25 mm thrust shim (B), and the transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D).
11. Install the tapered roller bearing (A), the 25mm thrust shim (B), and the transfer hypoint drive gear/shaft assembly (C) to the transfer housing (D).
12. Install the transfer cover (E) and the bolts, and tighten the bolts. Do not install the O-ring on the transfer cover.
13. Rotate the companion flange 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: 0.06-0.17 mm (0.002-0.007 in.)
16. Remove the transfer cover, the transfer hypoid drive gear/shaft assembly, and check the transfer hypoid drive gear tooth contact pattern.
17. If the measurement of the backlash is out of the standard, adjust the transfer gear backlash with the 40 mm thrust shim and recheck. Do not use more than two 40 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 40 mm thrust shim. Do not use more than two shims of each thrust shim to adjust the tooth contact.
^ Toe Contact
Use a thinner 40 mm thrust shim to move the transfer output shaft (hypoid gear) away from the transfer hypoid drive gear. Because this movement causes the transfer gear backlash to change, move the transfer hypoid 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 80 mm thrust shim by amount of reduce thickness of the 25 mm thrust shim.
^ Heel Contact
Use a thicker 40 mm thrust shim to move the transfer output shaft (hypoid gear) toward the transfer hypoid drive gear. Because this movement causes the transfer backlash to change, move the transfer hypoid 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 80 mm thrust shim by the amount of increase thickness of the 25 mm thrust shim.
^ Flank Contact
Use a thicker 25 mm thrust shim to move the transfer hypoid drive gear away from 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 thinner 25 mm thrust shim to move the transfer hypoid drive gear toward 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 hypoid 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 companion flange holder 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.
21. Remove the locknut (A), the conical spring washer (B), and the companion flange (C) from the transfer output shaft (hypoid gear) (D).
22. Remove the transfer output shaft (hypoid gear) from the transfer housing.
23. Install the two thrust washers (A) and a new transfer spacer (B) on the transfer output shaft (hypoid gear) (C) in the direction shown, and install them in the transfer housing (D).
24. Coat the threads of the locknut and transfer output shaft (hypoid gear) with ATF.
25. Install the companion flange (A), a new O-ring (B), back-up ring (C), a new conical spring washer (D), and a 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 companion flange holder 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 output shaft (hypoid gear) so the starting torque is within 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.).
Tightening 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 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.
28. Remove the companion flange holder.
29. Stake the locknut to a depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
30. Install the tapered roller bearing (A), the 25 mm thrust shim (B), and the transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D).
31. Temporarily install the transfer cover (E) without the O-ring. Install and tighten the bolts.
32. Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the companion flange holder 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.
33. Rotate the transfer companion flange (C) several times to seat the tapered roller bearings.
34. Measure the starting torque at the companion flange using a torque wrench (D) and a socket (E).
Total Starting Torque:
3.20-4.16 N.m
(32.6-42.4 kgf.cm, 28.3-36.8 lbf.in.)
35. Remove the transfer cover.
36. If the measurement is out of standard, remove the bearing outer race (A) and the 80 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 41.
37. Measure the thickness of removed 80 mm thrust shim, and select a new 80 mm shim.
38. Install the 80 mm trust shim (A) and bearing outer race (B) in the transfer cover (C). If you heated the cover, let it cool to room temperature before installing the thrust shim.
39. Drive the outer race securely in the cover with the driver and attachment (78 x 80 mm), so there is no clearance between the outer race, thrust shim, and cover.
40. After replacing the 80 mm thrust shim, recheck and make sure that the total starting torque is within the specification.
41. Install a new O-ring (A) on the transfer cover (B), then install the cover on the transfer housing (C).
42. Remove the filler plug (A), then refill the transfer with transfer fluid (hypoid gear oil) through the filler hole. Use an SAE 90 or SAE 80W-90 viscosity hypoid gear oil, API classified GL4 or GL5 only.
Viscosity
SAE 90: Above 0 °F (-18 CC) SAE 80W-90: Below 0 °F (-18 °C)
Hypoid Gear Oil Capacity: 0.45 L (0.48 US qt)
43. Install the filler plug with a new sealing washer (B).