Transfer case — assembly (Honda HR-V 1)

Note:

• When assembling the transfer case assembly:
• 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.
• Apply oil to all parts during assembly.
• If it is necessary to replace the tapered roller bearing or the bearing outer race, replace them together.
• If it is necessary to replace the transfer case pinion gear or driven gear shaft, replace them together.

Assembly order

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 clearances in the transfer case gears and the shape of 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: Number on the existing shaft of the transfer case driven gear.
Q: Number on the replacement shaft of the transfer case driven gear.
C: Thickness of existing 35mm thrust washer.
X: Required thickness to replace 35mm thrust washer.

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

EXAMPLE:



When replacing the tapered roller bearing on the transfer case driven gear shaft, use a 1.08 mm thick thrust washer.

Measure the thickness of the replacement bearing and the existing bearing. 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

Gasket 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 in the engagement and the shape of the contact patch 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.

Note: Use the old transfer case spacer to install the bearing, then discard it.

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 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. While 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 lock nut, apply oil to the threads of the lock nut and shaft.
• Do not taper the locknut at this stage.

9. Install the transfer case shaft assembly 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 lock nut, apply oil to the threads of the lock nut and shaft.
• Do not taper the locknut at this stage.

10. Place a 14mm socket wrench on the transfer case shaft from the gear side, then secure the wrench in a vice.

11. Tighten the lock nut on the transfer case shaft.

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 coupling flange, then measure the clearance in the transfer case gear.



15. If the measurement is not correct, remove the lock nut from the transfer case shaft and replace the 25mm thrust washer. Select and install a new 25mm thrust washer, then remeasure. Use no more than one 25mm thrust washer 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 shape on the transfer case gear teeth is incorrect, adjust using a 35mm or 25mm thrust washer.

Note:

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

1 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 of the 68mm thrust washer by the amount of the increase in thickness of the 25mm thrust washer.

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 offset to 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 normal limits, adjust as described for the tooth heel contact.

End contact

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

Remove the components from the transfer case shaft and remove the transfer case shaft from the crankcase

.

Checking and adjusting the starting element of the driven gear shaft of the accelerator box

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.

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.



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 lock nut, apply oil to the threads of the lock nut and the transfer case shaft.
• 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: 132-260 Nm (13.5-26.5 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 260 Nm (26.5 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, countersink the locknut onto the transfer case driven gear shaft as shown in the figure.



29. Install the transfer case shaft assembly 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 lock nut, apply oil to the threads of the lock nut and shaft.
• Install the conical spring washer in the direction shown.

30. Place a 14mm socket wrench on the transfer case shaft from the gear side, then clamp the wrench in a vice. Tighten the transfer case shaft lock nut. The lock nut has a left-hand thread.



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 the 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.

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



35. Remove cover A of the transfer case.

36. If the measurement differs from the specified value, remove the 68 mm thrust washer from the transfer case cover "A" by heating the cover to almost 100°C using 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 differs from the specified value, 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
ZZ	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-PW5-000	1.68 mm
F	23946-PW5-000	1.71 mm
G	23947-PW5-000	1.74 mm
N	23948-PW5-000	1.77 mm
I	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
ABOUT	23955-PW5-000	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-PW8-000	2.46 mm
BZ	23972-PW8-000	2.49 mm
CZ	23973-PW8-000	2.52 mm
DZ	23974-PW8-000	2.55 mm
EZ	23975-PW8-000	2.58 mm

38. Using the 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 the normal range.

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