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Special Tools Required

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NOTE: To prevent damage to the transfer housing, always use wood blocks or equivalent materials between the transfer housing and a vise.
  1. Remove the transfer assembly (see TRANSFER ASSEMBLY REMOVAL  ).
  2. Remove the transfer cover (A) from the transfer housing (B).
    Fig 1: Locating Transfer Cover And Transfer Housing
    G08057786Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Remove the transfer hypoid drive gear/shaft assembly (C).
  4. Remove the O-ring (D) from the transfer cover.
  5. Drain the transfer fluid (hypoid gear oil) from the transfer housing.
  6. Using a chisel, cut the lock tab (A) on the locknut (B).
    Fig 2: Cutting Lock Tab On Locknut Using Chisel
    G08057787Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Secure the transfer housing (A) in a bench vise (B) with wood blocks.
    Fig 3: Securing Transfer Housing In Bench Vise With Wood Blocks
    G08057788Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the flange holder on the companion flange, then loosen the locknut.
  9. Remove the flange holder.
  10. 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).
    Fig 4: Identifying Transfer Output Shaft (Hypoid Gear) Assembly
    G08057789Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B), then remove the thrust washer (C) and the transfer spacer (D) from the transfer output shaft (hypoid gear).
    Fig 5: Locating Transfer Output Shaft (Hypoid Gear), Transfer Housing, Thrust Washer And Transfer Spacer
    G08057790Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Remove the oil seal (A) from the transfer housing (B).
    Fig 6: Locating Oil Seal And Transfer Housing
    G08057791Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install a new oil seal flush with the transfer housing using the 15 x 135L driver handle and the 65 mm oil seal driver attachment.
    Fig 7: Installing Oil Seal Flush With Transfer Housing
    G08057792Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the thrust washer (A) and a new transfer spacer (B) on the transfer output shaft (hypoid gear) (C), and install them in the transfer housing (D).
    Fig 8: Locating Thrust Washer, Transfer Spacer, Transfer Output Shaft (Hypoid Gear) And Transfer Housing
    G08057793Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Coat the threads of the locknut and the transfer output shaft (hypoid gear) with transfer fluid (hypoid gear oil).
  16. Install the companion flange (A). Coat a new O-ring (B) with transfer fluid (hypoid gear oil), then install the O-ring, the 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.
    Fig 9: Locating Transfer Output Shaft Companion Flange Assembly
    G08057794Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Secure the transfer housing (A) in a bench vise (B) with wood blocks.
    Fig 10: Securing Transfer Housing In Bench Vise With Wood Blocks
    G08057795Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Install the flange holder on the companion flange.
  19. 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 turns 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.
  20. Remove the flange holder.
  21. Stake the locknut to a depth (A) at least 0.7 mm (0.03 in) using a 3.5 mm punch (B). Be careful not to make a crack on the locknut when staking.
    Fig 11: Staking Locknut To Depth At Least 0.7 mm (0.03 in) Using 3.5 mm Punch
    G08057796Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Install the transfer hypoid drive gear/shaft assembly (A) in the transfer housing (B).
    Fig 12: Locating Transfer Hypoid Drive Gear/Shaft Assembly With Torque Specifications
    G08057797Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Install a new O-ring (C) on the transfer cover (D), then install the transfer cover on the transfer housing.
  24. Remove the filler plug (A), then refill the transfer assembly with transfer fluid (hypoid gear oil). Use an SAE 90 viscosity hypoid gear oil, API classified GL4 or GL5 only.

    Viscosity: 

    SAE 90: Above 0°F (-18°C) 

    Hypoid Gear Oil Capacity: 0.45 L (0.48 US qt) 

    Fig 13: Locating Filler Plug And Sealing Washer With Torque Specifications
    G08057798Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Install the filler plug with a new sealing washer (B).
  26. Check the transfer gear backlash and the total starting torque (see INSPECTION  ).
  27. Install the transfer assembly (see TRANSFER ASSEMBLY INSTALLATION  ).
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