Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Transfer Assembly: Reassembly
Special Tools Required
- Driver, 40 mm I.D. 07746-0030100
- Attachment, 35 mm I.D. 07746-0030400
- Driver 07749-0010000
- Seal driver attachment 07GAD-PG40100 or 07GAD-PG40101
- Companion flange holder 07XAB-0020100
- Attachment, 72 x 75 mm 07746-0010600
- While reassembling the transfer assembly:
- Check and adjust the transfer gear tooth contact.
- Measure and adjust the transfer gear backlash.
- Check and adjust the tapered roller bearing starting torque.
- Coat all parts with ATF during reassembly.
- Replace the tapered roller bearing and the bearing outer race as a set if either part is replaced.
- Replace the transfer hypoid drive gear and the transfer output shaft (hypoid gear) as a set if either part is replaced.
- Select the 40 mm thrust shim if the transfer output shaft (hypoid gear) is replaced. Calculate the thickness of the 40 mm thrust shim using the formula below, and select the shim from the following table.
FORMULA: A/100 - B/100 + C = X
A: Number on the existing transfer output shaft (hypoid gear)
B: Number on the replacement transfer output shaft (hypoid gear)
C: Thickness of the existing 40 mm thrust shim
X: Thickness needed for the replacement 40 mm thrust shim
NOTE: The number on the transfer output shaft (hypoid gear) is shown in 1/100 mm.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.