Transfer Oil Seal Replacement

Special Tools Required 

• Flange Holder 07XAB-0010101
• Driver Handle, 15 x 135L 07749-0010000
• Oil Seal Driver Attachment, 65 mm 07JAD-SH30100

1. Remove the transfer assembly (see TRANSFER ASSEMBLY REMOVAL  ).
2. Remove the transfer cover (A) from the transfer housing (B).
   Fig 1: Removing Transfer Cover From Transfer Housing

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Remove the transfer hypoid drive gear/shaft assembly (C), 25 mm thrust shim (D), and tapered roller bearing (E).
4. Remove the O-ring (F) from the cover.
5. Drain the transfer fluid (hypoid gear oil) from the transfer housing.
6. Cut the lock tab on the locknut using a chisel.
   Fig 2: Cutting Lock Tab On Locknut Using Chisel

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Secure the transfer housing (A) in a bench vise (B) with soft jaws.
   Fig 3: Securing Transfer Housing In Bench Vise With Soft Jaws

   Courtesy 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: Removing Locknut, Conical Spring Washer And Companion Flange From Transfer Output Shaft

    Courtesy 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: Removing Transfer Output Shaft (Hypoid Gear) From Transfer Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
12. Remove the oil seal (A) from the transfer housing.
    Fig 6: Removing Oil Seal From Transfer Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Install a new oil seal flush with the transfer housing using the driver handle and the oil seal driver attachment.
    Fig 7: Installing Oil Seal Flush With Transfer Housing Using Driver Handle And Oil Seal Driver Attachment

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Install the thrust washer (A) and the new transfer spacer (B) on the transfer output shaft (hypoid gear) (C), and install them in the transfer housing (D).
    Fig 8: Installing Thrust Washer And Transfer Spacer On Transfer Output Shaft

    Courtesy 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: Installing O-Ring, Back-Up Ring, Conical Spring Washer And Locknut On Transfer Output Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Secure the transfer housing (A) in the bench vise (B) with soft jaws.
    Fig 10: Securing Transfer Housing In Bench Vise With Soft Jaws

    Courtesy 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 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.
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).
    NOTE: Be careful not to make a crack on the locknut when staking.
    Fig 11: Staking Locknut

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer hypoid drive gear/shaft assembly (C) in the transfer housing (D).
    Fig 12: Installing Tapered Roller Bearing, Thrust Shim And Transfer Hypoid Drive Gear/Shaft Assembly With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Install a new O-ring (E) on the transfer cover (F), 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 

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

    Fig 13: Installing Transfer Cover On Transfer Housing With Torque Specifications

    Courtesy 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 TRANSFER GEAR BACKLASH MEASUREMENT  ).
27. Install the transfer assembly (see TRANSFER ASSEMBLY INSTALLATION  ).