Overhaul - Transfer Case: Diagnosis Honda Pilot I

Transfer Thrust Clearance Inspection

Note. If the transfer output shaft, transmission housing, or torque converter housing is replaced, the output shaft thrust clearance must be adjusted with the 24 mm thrust shim.

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1. Install the transfer output shaft in the torque converter housing.
2. Measure the distance (A) between the torque converter housing surface (B) and the 24 mm thrust shim mounting surface (C) of the transfer output shaft, then note the measurement (Measurement A).
3. Measure the distance (B) between the transmission housing surface (C) and the bearing inner race (D), then note the measurement (Measurement B). Do not push the bearing inner race while measuring the distance.
4. Calculate the thickness of the 24 mm thrust shim using the formula below. Formula: Output Shaft Thrust Clearance Including 24 mm Thrust Shim Thickness = Measurement B - Measurement A + Transmission Housing Gasket Thickness (0.5 +/- 0.1 mm) Output Shaft Thrust Clearance Standard: 0-0.484 mm (0-0.019 in.) Example: Measurement A: 37.0 mm (1.475 in.) Measurement B: 38.5 mm (1.516 in.) 24 mm Thrust Shim Thickness: Thick = 38.5 - 37.0 + (0.5 + 0.01) + 0.01 - 0.0484 = 1.626 Thin = 38.5 - 37.0 + (0.5 - 0.1) - 0.01 = 1.890
5. You can use the shims number A, B, or C in this case. Select the 24 mm thrust shim from the following table.

Inspection

Note. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and a vise.

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1. Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt hole center (D).
2. Measure the transfer gear backlash. Standard: 0.06-0.16 mm (0.02-0.06 in.) Total Starting Torque Measurement
3. Rotate the companion flange several times to seat the tapered roller bearings.
4. Measure the starting torque at the companion flange (A) using a torque wrench (B). Standard: 2.65-4.75 N.m (27.0-48.5 kgf.cm, 23.5-42.0 lbf.in.) Transfer Gear (Hypoid Gear) Tooth Contact Inspection
5. Remove the transfer cover (A) from the transfer housing (B), and remove the O-ring (C) from the transfer cover.
6. Remove the transfer drive gear/shaft assembly (D), 25 mm thrust shim (E), and tapered roller bearing (F).
7. Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
8. Install the tapered roller bearing, 25 mm thrust shim, and transfer drive gear/shaft assembly in the transfer housing.
9. Install the transfer cover, and tighten the bolts. Do not install the O-ring on the transfer cover.
10. Rotate the companion flange in both directions until the transfer gear rotates one full turn in both directions.
11. Remove the transfer cover and transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern. The pattern should be centered on the gear teeth as shown.
12. If the measurements are out of standard or the tooth pattern is not correct, disassemble the transfer assembly and repair it.

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