Transfer case assembly (Honda HR-V 1)

Note: When assembling the transfer case:

• Check and adjust the shape of the contact patch of the transfer case gear teeth.
• Measure and adjust the clearance in the transfer case gears.
• Check and adjust the starting torque of the tapered roller bearing.

Note:

• Apply transmission fluid to all parts during assembly.
• If it is necessary to replace the tapered roller bearing or bearing outer race, replace them as an assembly.
• If it is necessary to replace the transfer case drive gear or driven gear shaft, replace them as an assembly.

Assembly Summary

1. Select a 35mm thrust washer.

Perform this procedure if replacing the transfer case driven gear shaft or the tapered roller bearing on the transfer case driven gear shaft.

2. Pre-assemble all components, check and adjust the clearance in the transfer case gears and the contact patch of the transfer case gear teeth.

3. Disassemble the components, then assemble the transfer case driven gear shaft and related parts.



4. Measure and adjust the starting torque of the tapered roller bearing of the transfer case driven gear shaft.

5. Assemble the transfer case shaft and related parts.

6. Measure and adjust the total starting torque.

Selection of thrust washer 35 mm

1. Select a 35mm thrust washer when replacing the transfer case driven gear shaft or the tapered roller bearing on the transfer case driven gear shaft.

Calculate the thickness of the 35mm thrust washer using the following formula:

FORMULA: A/100 - B/100 + C = X

A: The number on the existing shaft of the transfer case driven gear.
Q: Number on the replacement shaft of the transfer case driven gear.
C: The thickness of the existing thrust washer is 35 mm.
X: The required thickness of the replacement thrust washer is 35 mm.

Note: The number on the transfer case driven gear shaft is indicated in 1/100 mm.

EXAMPLE: X = A/100 - B/100 + C = 2/100 - (-1/100) + 1.05 = 0.02 + 0.01 + 1.05 = 1.08 mm



If replacing the tapered roller bearing on the transfer case driven gear shaft, select a 35 mm, 1.08 mm thick thrust washer.

Measure the thickness of the replacement bearing and the existing bearing and calculate the difference in bearing thickness. Adjust the thickness of the existing 35mm thrust washer to account for the difference in bearing thickness and select a replacement 35mm thrust washer.

Thrust washer, 35 mm

Washer No	Catalogue No	Thickness
A	41361-PS3-000	0.72 mm
IN	41362-PS3-000	0.75 mm
WITH	41363-PS3-000	0.78 mm
D	41364-PS3-000	0.81 mm
E	41365-PS3-000	0.84 mm
F	41366-PS3-000	0.87 mm
G	41367-PS3-000	0.90 mm
N	41368-PS3-000	0.93 mm
I	41369-PS3-000	0.96 mm
J	41370-PS3-000	0.99 mm
TO	41371-PS3-000	1.02 mm
L	41372-PS3-000	1.05 mm
M	41373-PS3-000	1.08 mm
N	41374-PS3-000	1.11 mm

Checking the clearance and shape of the contact spot of the teeth in the transfer case gears

2. Install the 35mm thrust washer onto the transfer case driven gear shaft, then use the special tool to press in the tapered roller bearing as shown in the figure.



3. Place the tapered roller bearing on the outer bearing ring on the transfer case connecting flange side.

4. Using a special tool, press the new oil seal into the transfer case housing.



5. Install the transfer case driven gear shaft into the transfer case housing. Do not install the transfer case bushing onto the transfer case driven gear shaft at this stage.





6. Install the coupling flange, conical spring washer and lock nut onto the transfer case driven gear shaft. Do not install the O-ring and protective ring onto the transfer case shaft at this stage.



7. Secure the transfer case housing in a vice with soft jaws, then install the special tool on the coupling flange. To avoid damaging the transfer case housing, always secure it in a vice with soft jaws or insert a gasket between the vice and the transfer case.

8. When tightening the lock nut, measure the starting torque so that it is within 0.98-1.39 Nm (10.0-14.2 kgf/cm)

Note:

• Before installing the locknut, apply transmission fluid to the locknut and shaft threads.
• Do not taper the locknut at this stage.

Starting torque: 0.98-1.39 Nm (10.0-14.2 kgf/cm).





9. Install the transfer case shaft into the transfer case housing, then install the tapered roller bearing, transfer case shaft bushing, 25mm thrust washer, transfer case pinion gear, tapered spring washer and locknut onto the transfer case shaft (see illustration on next page, top left column).

Note:

• Before installing the locknut, apply transmission fluid to the locknut and shaft threads.
• Do not taper the locknut at this stage.

10. Place a 14mm socket wrench on the gear side of the transfer case shaft, then secure the wrench in a bench vise.



11. Tighten the lock nut on the transfer case shaft. Tightening torque: 118 Nm (12.0 kgf/m).

Note:

• The transfer case shaft lock nut has a left-hand thread.
• Do not taper the locknut at this stage.

12. Temporarily install transfer case cover A without the O-ring.





13. Rotate the coupling flange several times to seat the tapered roller bearing.

14. Install the indicator head on the connecting flange, then measure the clearance of the transfer case gear. Standard: 0.06-0.16 mm



15. If the measurement is different from the standard value, loosen the lock nut from the transfer case shaft and replace the 25 mm thrust washer. Select and install a new 25 mm thrust washer, then remeasure. Use no more than two 25 mm thrust washers to adjust the transfer case gear clearance.

Thrust washer, 25 mm

Gasket No	Catalogue No	Thickness
1	29411-P1C-000	1.70 mm
2	29412-P1C-000	1.73 mm
3	29413-P1C-000	1.76 mm
4	29414-P1C-000	1.79 mm
5	29415-P1C-000	1.82 mm
6	29416-P1C-000	1.85 mm
7	29417-P1C-000	1.88 mm
8	29418-P1C-000	1.91 mm
9	29419-P1C-000	1.94 mm
10	29420-P1C-000	1.97 mm
11	29421-P1C-000	2.00 mm
12	29422-P1C-000	2.03 mm
13	29423-P1C-000	2.06 mm
14	29424-P1C-000	2.09 mm
15	29425-P1C-000	2.12 mm
16	29426-P1C-000	2.15 mm
17	29427-P1C-000	2.18 mm
18	29428-P1C-000	2.21 mm
19	29429-P1C-000	2.24 mm

16. Apply a thin layer of red lead evenly to both sides of the transfer case gear teeth.



17. Rotate the coupling flange in both directions until the transfer case gear has turned one full revolution in both directions.

18. Check the shape of the contact patch on the transfer case gear teeth.



19. If the contact patch on the transfer case gear teeth is incorrect, adjust it using a 35mm or 25mm thrust washer.

Note:

• See 35mm thrust washer selection procedure above.
• To adjust the contact patch on the transfer case gear teeth, use no more than two 35mm thrust washers.
• See 25mm thrust washer selection procedure above.
• To adjust the contact patch on the transfer case gear teeth, use no more than two 25 mm thrust washers.

Contact at the tip of the tooth

To move the transfer case driven gear shaft toward the pinion gear, use a thicker 35mm thrust washer. Since this movement changes the transfer case pinion gear clearance, to adjust the transfer case pinion gear clearance, move the pinion gear away from the driven gear shaft as follows:

• Increase the thickness of the thrust washer to 25mm.
• Reduce the thickness by the amount of the 25mm thrust washer thickness increase.

Contact at the heel of the tooth

To move the transfer case driven gear shaft away from the pinion gear, use a thinner 35mm thrust washer. Since this movement changes the transfer case pinion clearance, to adjust the transfer case pinion clearance, move the pinion gear toward the driven gear shaft as follows:

• Reduce the thickness of the 25mm thrust washer.
• Increase the thickness of the 68mm thrust washer by the amount of the 25mm thrust washer thickness reduction.

Contact patch shifted towards the tooth leg

To move the pinion gear toward the transfer case driven gear shaft, use a thinner thrust washer. The contact patch offset toward the tooth root should be adjusted within the transfer case pinion clearance. If the clearance exceeds the limits, adjust as described for the contact at the tooth heel.

Contact in the end plane

To move the pinion gear away from the transfer case driven gear shaft, use a thicker thrust washer. The face contact should be adjusted within the clearance in the transfer case pinion gear. If the clearance exceeds the limits, adjust as described for the nose contact.

20. Remove the components from the transfer case shaft and remove the transfer case shaft from the transfer case housing.

Checking and adjusting the starting torque of the driven gear shaft of the transfer case

21. Secure the transfer case housing in a vice with soft jaws. To avoid damaging the transfer case housing, always secure it in a vice with soft jaws or insert a spacer between the vice and the transfer case.

22. Install the special tool on the coupling flange, then unscrew the lock nut from the transfer case driven gear shaft and remove the conical spring washer.



23. Remove the transfer case driven gear shaft and connecting flange.

24. Install the new bushing onto the transfer case driven gear shaft, then install them into the transfer case housing.



25. Install the coupling flange, O-ring, backing ring, conical spring washer and locknut onto the transfer case driven gear shaft.

Note:

• Before installing the locknut, apply transmission fluid to the locknut and transfer case shaft threads.
• Install the conical spring washer in the direction shown.

26. Secure the transfer case housing in a vice with soft jaws. To avoid damaging the transfer case housing, always secure it in a vice with soft jaws or insert a spacer between the vice and the transfer case.

27. Install the special tool on the connecting flange, then tighten the lock nut on the shaft of the driven gear of the transfer case, measure the starting torque.

• Starting torque: 0.98-1.39 Nm (10.0-14.2 kgf/cm)
• Tightening torque: 132-216 Nm (13.5-22.0 kgf/m)

Note:

• Rotate the coupling flange to seat the tapered roller bearing, then measure the starting torque.
• If the starting torque exceeds 1.39 Nm (14.2 kgf/cm), replace the transfer case bushing and reassemble the components. Do not adjust the starting torque with the lock nut loose.
• If the tightening torque exceeds 216 Nm (22.0 kgf/m), replace the transfer case bushing and reassemble the components.
• Record the starting torque measurement results; they will be useful when measuring the total starting torque.

28. Using a 3.5mm punch, tap the lock nut onto the transfer case driven gear shaft as shown.



29. Install the transfer case shaft into the transfer case housing, then install the tapered roller bearing, transfer case shaft bushing, 25mm thrust washer, transfer case pinion gear, tapered spring washer and locknut onto the transfer case shaft.

Note:

• Before installing the locknut, apply transmission fluid to the locknut and shaft threads.
• Install the conical spring washer in the direction shown.

30. Place a 14 mm socket wrench on the transfer case shaft from the gear side, then secure the wrench in a bench vice. Tighten the transfer case shaft lock nut. (The lock nut has a left-hand thread). Tightening torque: 118 Nm (12.0 kgf/m).



31. Use a 3.5mm punch to countersink the lock nut onto the transfer case shaft.

Checking and adjusting the total starting torque

32. Temporarily install transfer case cover A without the O-ring.



33. Clamp the transfer case housing in a soft jaw vice, then rotate the coupling flange several times to seat the tapered roller bearing. To avoid damaging the transfer case housing, always clamp it in a soft jaw vice or insert a spacer between the vice and the transfer case.

34. Measure the total starting torque. Total starting torque: 1.70-2.08 Nm (17.3-21.2 kgf/cm) + the value of the starting torque of the transfer case driven gear shaft (recorded in item 27).



35. Remove cover A of the transfer case.

36. If the measurement is out of tolerance, remove the 68mm thrust washer from transfer case cover A by heating the cover to almost 100°C with a fan heater. Do not heat the cover to a temperature higher than 100°C. Allow the cover to cool to room temperature before adjusting the starting torque. If the measurement is out of tolerance, proceed to step 40.



37. Select a 68mm thrust washer.

Thrust washer, 68 mm

Gasket No	Catalogue No	Thickness
ZV	23974-P1C-020	1.41 mm
ZW	23975-P1C-020	1.44 mm
ZX	23976-P1C-020	1.47 mm
ZY	23977-P1C-020	1.50 mm
TL	23978-P1C-020	1.53 mm
A	23941-PW5-000	1.56 mm
IN	23942-PW5-000	1.59 mm
WITH	23943-PW5-000	1.62 mm
D	23944- PW5-000	1.65 mm
E	23945-FW5-000	1.68 mm
F	23946-PW5-000	1.71 mm
G	23947-PW5-000	1.74 mm
N	23948-PW5-000	1.77 mm
1	23949-PW5-000	1.80 mm
J	23950-PW5-000	1.83 mm
TO	23951-PW5-000	1.86 mm
L	23952-PW5-000	1.89 mm
M	23953-PW5-000	1.92 mm
N	23954-PW5-000	1.95 mm
0	23955-FW5-000	1.98 mm
R	23956-PW5-000	2.01 mm
Q	23957-PW5-000	2.04 mm
R	23958-PW5-000	2.07 mm
S	23959-PW5-000	2.10 mm
T	23960-PW5-000	2.13 mm
and	23961-PW5-000	2.16 mm
V	23962-PW5-000	2.19 mm
W	23963-PW5-000	2.22 mm
X	23964-PW5-000	2.25 mm
U	23965-PW5-000	2.28 mm
Z	23966-PW5-000	2.31 mm
AA	23967-PW5-000	2.34 mm
AB	23968-PW5-000	2.37 mm
AC	23969-PW5-000	2.40 mm
AD	23970-PW5-000	2.43 mm
AZ	23971-PW5-000	2.46 mm
BZ	23972-PW5-000	2.49 mm
CZ	23973-PW5-000	2.52 mm
DZ	23974-PW5-000	2.55 mm
EZ	23975-PW5-000	2.58 mm

38. Using a special tool, press in the 68mm thrust washer.



39. After replacing the 68mm thrust washer, recheck to ensure that the full starting torque is within tolerance.

40. Install the O-rings on the transfer case covers A and B.



The text of the article is available on the website HONDABOOK