Transfer Assembly Reassembly

Transfer Assembly Reassembly

Special Tools Required

- Oil Seal Driver Attachment, 58 mm 07JAD-PH80101
- Companion Flange Holder 07RAB-TB4010A or 07RAB-TB4010B
- Holder Handle 07JAB-001020A
- Bearing Driver Attachment, 72 x 75 mm 07746-0010600
- Driver Handle, 40 mm I.D. 07746-0030100
- Bearing Driver Attachment, 35 mm I.D. 07746-0030400
- Driver Handle, 15 x 135L 07749-0010000

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 tapered roller bearing outer race as a set if either part is replaced.
- Replace the transfer drive gear (hypoid gear) and the transfer output shaft (hypoid gear) as a set if either part is replaced.
- To prevent damaging the transfer housing, always use soft jaws or equivalent materials between the transfer housing and a vise.

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 following formula, and select the shim from the following table.









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

Example





THRUST SHIM, 35 mm





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 the difference in bearing thickness, and select the replacement 35 mm thrust shim.

3. Install the 35 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) using the driver handle (40 mm I.D.), the attachment (35 mm I.D.), and a press.






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





5. Install a new oil seal (B) on the transfer housing using the driver handle (15 x 135L) and the oil seal driver attachment (58 mm).

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 (hypoid gear).






7. Install the companion flange (A), the conical spring washer (B) in the direction shown, and a new locknut (C) on the transfer output shaft (hypoid gear) (D). Do not install the O-ring and the back-up ring.






8. Secure the transfer housing (A) in a bench vise (B) with soft jaws.





9. Install the companion flange holder and the holder handle on the companion flange.

10. Tighten the locknut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 0.98-1.39 Nm(10.0-14.2 kgf·cm,8.7-12.3 lbf·in). Do not stake the locknut in this step. Remove the companion flange holder and the holder handle.

11. Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (hypoid gear) (C), the transfer collar (D), the 25 mm thrust shim (E), the tapered roller bearing (F), the conical spring washer (G) in the direction shown, and a new locknut (H).






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





13. Tighten the locknut 118 Nm (12.0 kg-m,87 lb-ft). Do not stake the locknut in this step.

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

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





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

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





18. Measure the transfer gear backlash.






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





20. If the backlash measurement is out of the standard, adjust the backlash with the 35 mm thrust shim and recheck. Do not use more than two 35 mm thrust shims to adjust the backlash.

21. If the transfer gear tooth contact is incorrect, adjust the tooth contact with the 25 mm, 35 mm, or 75 mm thrust shim. Do not use more than two shims of each thrust shim to adjust the tooth contact.

- Toe Contact
Use a thinner 35 mm thrust shim in step 1 Transfer Assembly Reassembly to move the transfer output shaft (hypoid gear) away from the transfer drive gear (hypoid gear). Because this movement causes the transfer gear backlash to change, move the transfer drive gear (hypoid 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 (see step 41 Transfer Assembly Reassembly) by the amount you increased the 25 mm thrust shim.

- Heel Contact
Use a thicker 35 mm thrust shim in step 1 Transfer Assembly Reassembly to move the transfer output shaft (hypoid gear) toward the transfer drive gear (hypoid gear). Because this movement causes the transfer gear backlash to change, move the transfer drive gear (hypoid 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 (see step 41 Transfer Assembly Reassembly) by amount you reduced the thickness of the 25 mm thrust shim.

- Flank Contact
Use a thicker 25 mm thrust shim to move the transfer drive gear (hypoid 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 drive gear (hypoid 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.

THRUST SHIM, 25 mm





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 the bench vise (B) with soft jaws.





24. Install the companion flange holder and the holder handle on the companion flange, loosen the locknut, and remove the companion flange holder and the holder handle.

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






26. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B).





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

28. Coat the threads of the locknut and the transfer output shaft with ATF.

29. Install the companion flange (A), a new O-ring (B), the back-up ring (C), a new conical spring washer (D), and the locknut (E) on the transfer output shaft (hypoid gear) (F). Install the conical spring washer in the direction shown.






30. Secure the transfer housing (A) in the bench vise (B) with soft jaws.





31. Install the companion flange holder and the holder handle on the companion flange.

32. Tighten the locknut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 0.98-1.39 Nm (10.0-14.2 kgf·cm, 8.7-12.3 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 1.39 Nm (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 Nm (26.5 kg-m, 192 lb-ft), replace the transfer spacer and reassemble the parts.

33. Remove the companion flange holder and the holder handle.

34. Stake the locknut to a depth (A) of at least 0.7 mm (0.03 in) using a 3.5 mm punch (B).

NOTE: Be careful not to make a crack on the locknut when staking.






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






36. Secure the transfer housing (A) in the bench vise (B) with soft jaws.





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

38. Measure the total starting torque at the companion flange using a torque wrench (D) and a socket (E).

39. Calculate the transfer shaft starting torque using the following formula.









40. Check that the calculated transfer shaft starting torque within the following reference value range.





- If the calculated transfer shaft starting torque is within the reference value range, remove the transfer holder from the transfer housing, then go to step 53 Transfer Assembly Reassembly.
- If the calculated transfer shaft starting torque is out of the reference value range, remove the transfer holder from the transfer housing, then go to step 41 Transfer Assembly Reassembly.

41. Put the 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in the bench vise.





42. Loosen the locknut.

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





44. Remove the tapered roller bearing (C), the 25 mm thrust shim (D), the transfer collar (E), the transfer drive gear (hypoid gear) (F), and the transfer shaft (G) from the transfer holder (H).

45. Remove the tapered roller bearing outer race (A) and the 75 mm thrust shim (B) from the transfer holder (C).





46. Measure the thickness of the 75 mm thrust shim, and select a new 75 mm thrust shim.

THRUST SHIM, 75 mm





47. Install a new 75 mm thrust shim (A) in the transfer holder, then install the tapered roller bearing outer race (B) using the driver handle (15 x 135L) and the attachment (72 x 75 mm).






48. Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (hypoid gear) (C), the transfer collar (D), the 25 mm thrust shim (E), the tapered roller bearing (F), a new conical spring washer (G), and the locknut (H). Install the conical spring washer in the direction shown.






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





50. Tighten the locknut 118 Nm (12.0 kg-m, 87 lb-ft). Do not stake the locknut in this step.

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





52. Rotate the companion flange several times to seat the tapered roller bearings, and recheck the starting torque. Remove the transfer holder after adjusting the starting torque.

53. Stake the locknut to a depth (A) of at least 0.7 mm (0.03 in) using a 3.5 mm punch (B).

NOTE: Be careful not to make a crack on the locknut when staking.






54. Install a new O-ring (A) on the transfer holder (B), then install the transfer holder with the dowel pin (C) on the transfer housing (D).