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Home >> Subaru >> 1988 >> XT DL >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - 4 & 5-Speed >> Final Assembly >> Introduction >> 4WD Dual Range

4WD Dual Range

  1. Remove lock plate, lock washer and transfer drive gear from drive pinion. Measure bearing protrusion and select proper bearing plate. Fit transfer case assembly with gasket and plate on main case and tighten bolts.
  2. Transfer drive gear should be installed when clearance between main case and transfer case becomes approximately .394" (10 mm). Install lock washer and lock nut on drive pinion. When tightening, the gear should be shifted to the 1st position.
  3. High-low shifter lever should be shifted to "HI" or "LO" position. After tightening nut, stake it. Install "O" ring in the side of high-low shifter rail bushing. Apply grease to plunger and fit into high-low shifter arm. Fit shifter fork rail spring and ball in transfer case, and install high-low shifter rail with high-low shifter arm.
  4. Punch in straight pin into high-low shifter rail. Install extension assembly with transfer rear gasket and tighten. Before tightening, ensure that shifter arm center pivot can be shifted to any selected direction. Apply gear oil on shifter arm center pivot, and ensure oil seal fits.
  5. Transfer drive and transfer driven gears should engage each other. Fit plunger, shifter fork rail spring and ball into transfer shifter fork, and install it to synchronizer sleeve. Apply gear oil to interlock rail, fit "O" ring to rail and insert rail into transfer case.
  6. Punch in clip onto interlock rail groove, and insert knock pin into interlock rail hole. Install transfer ball joint assembly to transfer shifter rail. Adjust to 6.7-7.2" (171-185 mm) and tighten nut. Fit shifter fork rail spring and ball in transfer case, and install transfer shifter rail center pivot with transfer case in "4WD HI" so interlock mechanism does not operate
  7. Fit clip onto transfer shifter rail groove. Fit nut, rod adjusting screw, nut and ball joint assembly to high-low shifter rod. Shorten linkage length by turning turnbuckle clockwise.
  8. Insert rod arm into rear portion of high-low shifter rod, and punch in straight pin. Connect rod ball joint assembly with high-low shifter lever center pivot and tighten nut to the specified torque. Confirm operation by moving rod back and forth.
  9. Shift transfer shifter rail into "4WD LO" position and fix high-low shifter rail by inserting stopper pin into its hole. Shift high-low shifter lever into LO position and lengthen linkage by turning turnbuckle counterclockwise while holding high-low shifter rod. Align holes of rod arm and high-low shifter rod, and punch in straight pin.
  10. While holding rod ball joint assembly, turn rod adjusting screw counterclockwise and then turn back 90° clockwise at the point where ball joint movement becomes tight. Tighten rear nut, and then tighten front nut while holding rod ball joint assembly. Pull out stopper pin and confirm shift operation.
  11. Install transfer case cover with gasket and tighten bolts. Insert a bar through shifter arm hole and shift gear to 3rd gear position. Shifter arm should turn lightly toward the 1st-2nd gear side and heavily toward the reverse side.
  12. Remove plug on the transfer case and change the thickness of the aluminum gasket to adjust the heavy stroke (reverse side) to be the same as the light stroke. Install clutch release fork and release bearing holder by installing retainer spring into fork.
  13. While pushing fork to pivot and twisting it to fit both sides, fit retainer spring onto constricted portion of pivot. Install holder and fasten with 2 clips. Install release fork seal ring.
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