Transfer Oil Seal Replacement

Special Tools Required 

• Driver Handle, 15 x 135L 07749-0010000
• Oil Seal Driver Attachment, 65 mm 07JAD-SH3010A
• Flange Holder 07XAB-0010101

1. Remove the transfer assembly (see TRANSFER ASSEMBLY REMOVAL  ).
2. Remove the transfer cover (A) from the transfer housing (B).
   Fig 1: Identifying Transfer Cover And Transfer Housing With Transfer Hypoid Drive Gear/Shaft Assembly

   Courtesy 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

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7. Secure the transfer housing (A) in a bench vise (B) with wood blocks.
   Fig 3: Securing Transfer Housing In Bench Vise

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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 Locknut, Conical Spring Washer, Back-Up Ring, O-Ring, Companion Flange And Transfer Output Shaft (Hypoid Gear)

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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: Identifying Transfer Output Shaft (Hypoid Gear), Transfer Housing, Thrust Washer And Transfer Spacer

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12. Remove the oil seal (A) from the transfer housing (B).
    Fig 6: Identifying Oil Seal And Transfer Housing

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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 Into Transfer Housing

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14. Install the thrust washer (A) and a new transfer spacer (B) on the transfer output shaft (hypoid gear) (C) in the direction shown illustration, and install them in the transfer housing (D).
    Fig 8: Identifying Thrust Washer, Transfer Spacer, Transfer Output Shaft (Hypoid Gear) And Transfer Housing

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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 in illustration.
    Fig 9: Identifying Companion Flange, O-Ring, Transfer Fluid (Hypoid Gear Oil), Back-Up Ring, Conical Spring Washer And Locknut

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17. Secure the transfer housing (A) in a bench vise (B) with wood blocks.
    Fig 10: Securing Transfer Housing In Bench Vise

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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, 10.18-15.14 lbf.in). Tighten the locknut to the lower torque specification, then check the starting torque. If the starting torque is low, increase the torque on the locknut until the starting torque is acceptable.

    Tightening Torque: 

    108-294 N.m (11.0-30.0 kgf.m, 80-217 lbf.ft) 

    Starting Torque: 

    1.115-1.71 N.m (11.7-17.4 kgf.cm, 10.18-15.14 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, 15.14 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 into the shaft to a depth (A) at least: 0.7 mm (0.028 in) using a 3.5 mm punch (B). Be careful not to make a crack on the locknut when staking.
    Fig 11: Staking Locknut Into Shaft To Depth

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22. Install the transfer hypoid drive gear/shaft assembly (A) in the transfer housing (B).
    Fig 12: Transfer Hypoid Drive Gear/Shaft Assembly, Transfer Housing, O-Ring And Transfer Cover With Torque Specifications

    Courtesy 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) 

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

    Fig 13: Filler Plug With Sealing Washer With Torque Specifications

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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  ).