PPG Gears K Series AWD Transfer Case Hypoid Gears

PPG Gears K Series AWD Transfer Case Hypoid Gears (Spider Gears)

You're building an AWD K series setup for serious power and the stock transfer case hypoid gears aren't going to survive. The stock hypoid gears are cast. They're designed for a CR-V making 160 hp and driving to the grocery store. They're not designed for a turbocharged K24 making 800 whp and launching at 6000 RPM on slicks. PPG's hypoid gear set replaces the stock cast hypoid gears with motorsports-grade billet steel gears. These are the gears that change the direction of power 90 degrees inside your transfer case. They take power from the front differential's ring gear and transfer it to the transfer case shaft that drives the driveshaft. The stock gears strip. They crack. They explode under high torque loads. We've seen stock hypoid gears fail at 500 whp from hard launches. PPG's hypoid gears are machined from billet steel. They're built to handle extreme duty applications. This is what you install when you're making 1000+ hp and you need the transfer case to actually survive.

Here's What Hypoid Gears Do and Why Stock Ones Fail

Hypoid gears are a type of spiral bevel gear where the pinion (small gear) and the ring gear (large gear) have offset axes that don't intersect. That offset design lets the gears handle way more torque than regular bevel gears because there's more tooth contact area and the pinion can be larger. In your AWD transfer case, the hypoid gears are what connect the front differential to the transfer case shaft. The differential's got an extra ring gear on it that drives the hypoid pinion. The hypoid pinion meshes with the hypoid ring gear. The ring gear's mounted to the transfer case shaft. That's how power gets from the front wheels to the rear driveshaft. It's a 90-degree change in direction. The stock hypoid gears are cast steel. Honda designed them for a stock CR-V that's never going to see hard launches or high power. When you're making 600-1000 whp and you're launching hard, the stock gears can't handle the torque. The teeth strip. The gears crack. Sometimes they just explode and take out the entire transfer case. PPG's hypoid gears are machined from motorsports-grade billet steel. The teeth are thicker. The material's stronger. They're not going to strip when you're making boost and dumping the clutch.

Installation Requires Precise Shimming and Setup

Here's the reality about hypoid gears. They're not a drop-in part. You can't just pull the stock gears out and bolt the PPG gears in. Hypoid gears require precise backlash and preload settings. The backlash needs to be between 0.05mm and 0.10mm. The preload on the driven wheel shaft needs to be around 2 newton-meters. The preload on the drive gear shaft needs to be set correctly. You need to check the contact patch on the gear teeth to make sure the gears are meshing correctly. If the contact patch is off, you're adjusting shims until it's in the center of the tooth face. PPG includes an installation kit with bearing spacers, cups, cones, and shims. They also provide detailed installation instructions. Professional installation's highly recommended. This isn't a job you're doing in your driveway with basic tools. This is a job that requires a dial indicator, a torque wrench, gear marking compound, and someone who knows how to set up hypoid gears. If the setup's wrong, the gears will whine. They'll wear prematurely. They'll fail. Do it right or pay someone who knows what they're doing.

Works with PPG Transfer Shaft and Transfer Gears

PPG's hypoid gear set is part number HO-K4GAWD-Spider-GA. It's designed to work with PPG's transfer case shaft (HO-K4GDB-1258) and PPG's transfer gears (HO-K4GAWD-RWD-GA). Most people building serious AWD setups are buying the complete PPG transfer case combo. That's the hypoid gears, the transfer shaft, and the transfer gears. All billet. All designed to work together. You can buy the hypoid gears separately but if you're making enough power to need the PPG hypoid gears, you probably need the PPG shaft and transfer gears too. The stock shaft's hollow and it twists. The stock transfer gears are cast and they strip. Upgrade the whole system at once. The complete PPG setup is what's running in the 8-second and 9-second AWD drag cars. Hypoid gears, transfer shaft, transfer gears, all PPG. All built to handle 1000+ hp.

What You Get

• PPG K series AWD transfer case hypoid gear set - part number HO-K4GAWD-Spider-GA
• Motorsports-grade billet steel construction (not cast like stock gears)
• Designed for extreme duty applications (handles 1000+ hp)
• Direct replacement for stock CR-V/Element transfer case hypoid gears
• Includes installation kit (bearing spacers, cups, cones, shims)
• Detailed installation instructions included (requires precise shimming and setup)
• Works with PPG transfer shaft (HO-K4GDB-1258) and PPG transfer gears (HO-K4GAWD-RWD-GA)
• Compatible with stock transfer case housing or Drag Cartel billet transfer case
• Made by PPG (Pfitzner Performance Gearbox)

Fits These Setups

• Honda CR-V AWD K Series Transfer Case (2002-2006, 5-speed manual)
• Honda Element AWD K Series Transfer Case (2003-2011, 5-speed manual)
• Drag Cartel Transfer Case

Note: Hypoid gears only - does NOT include transfer case housing, transfer shaft, or transfer gears (sold separately). Also called spider gears. Replaces stock cast hypoid gears with motorsports-grade billet steel gears. Hypoid gears change power direction 90 degrees from front differential ring gear to transfer case shaft (which drives rear driveshaft). Stock gears fail at 500-600 whp from hard launches - PPG gears handle 1000+ hp. Part number HO-K4GAWD-Spider-GA. Includes installation kit with bearing spacers, cups, cones, and shims. Requires precise setup - backlash 0.05-0.10mm, preload 2Nm on driven wheel shaft, contact patch must be centered on tooth face. Professional installation HIGHLY recommended (requires dial indicator, torque wrench, gear marking compound, hypoid gear setup knowledge). Incorrect setup causes whine, premature wear, and failure. Works with PPG transfer shaft (HO-K4GDB-1258) and PPG transfer gears (HO-K4GAWD-RWD-GA). Compatible with stock aluminum transfer case housing or Drag Cartel billet 8620 steel transfer case. Common in 8-second and 9-second AWD drag cars when combined with complete PPG transfer case internals. Made by PPG (Pfitzner Performance Gearbox). Fits 2002-2006 CR-V and 2003-2011 Element AWD transmissions and AWD K series swaps using these transmissions. Race application only - not for street use per PPG installation instructions.