Snap Ring Selection Examples

If LP2-LP1 is less than .002", use a new snap ring whose thickness is same as that (hereinafter called "old snap ring") used on old primary pulley side.

If LP2-LP1 is equal to or greater than .002", but less than .005", use a new snap ring one selection higher in thickness than old snap ring.

If LP2-LP1 is equal to or greater than .005", but less than .008", use a new snap ring 2 selections higher in thickness than old snap ring.

If LP2-LP1 is equal to or greater than .008", but less than .011", use a new snap ring 3 selections higher in thickness than old snap ring.

If LP2-LP1 is equal to or greater than .011", but less than .015" use a new snap ring 4 selections higher in thickness than old snap ring.

If LP2-LP1 is equal to or greater than .015", but less than .018" use a new snap ring 5 selections higher in thickness than old snap ring.

If LP1-LP2 is less than .0004", use a new snap ring whose thickness is same as that used on old primary pulley side.

If LP1-LP2 is equal to or greater than .0004", but less than .004", use a snap ring one selection lower in thickness than old snap ring.

If LP1-LP2 is equal to or greater than .0004", but less than .007", use a new snap ring 2 selections lower in thickness than old snap ring.

If LP1-LP2 is equal to or greater than .007", but less than .010", use a new snap ring 3 selections lower in thickness than old snap ring.

If LP1-LP2 is equal to or greater than .010", but less than .013", use a new snap ring 4 selections lower in thickness than old snap ring.

If LP1-LP2 is equal to or greater than .013", but less than .016", use a new snap ring 5 selections lower in thickness than old snap ring

1. Install Secondary Pulley Puller (499195400) on secondary pulley and expand groove width to 2.05-2.09" (52.0-53.0 mm). Install belt on secondary pulley and engrave "V" grooves of primary and secondary pulleys with each other. While placing belt on primary pulley, position both pulleys into side cases. Ensure belt is installed in proper direction. Angle section of belt teeth should face direction of rotation.
2. Remove secondary pulley puller and clip bands. Install retainer and "O" ring as a unit and tighten bolts to 10-13 ft. lbs. (14-17 N.m). Install ratio sensor in groove of primary pulley. Pass rod through ratio sensor and into side case. Ensure stepped side of rod faces side case.
3. Install parking pawl into side case. Ensure pawl of guide end is inserted into hole of side case and spring is not caught between parking pawl and parking cam guide.
4. Clean mating surfaces of transmission case and side case. Apply Sealant (004403007) to surfaces. While inserting ratio sensor rod, engine brake pipe and parking pawl into holes in transmission case. Install transmission case to side case. Tighten bolts in sequence. See Figure.
   Fig 1: Side Case Tightening Sequence

   Courtesy of SUBARU OF AMERICA, INC.
5. Install needle bearing and reverse idler gear with shaft. Ensure spring pin is positioned in groove on transmission case by turning shaft. Install sleeve and hub assembly, fork and reverse driven gear on primary pulley as a unit.
6. While slightly lifting sleeve and hub assembly and reverse driven gear, install countergear with small diameter end facing downward. Ensure spring pin is positioned in groove on transmission case by turning shaft. Install outer snap ring. Install needle bearing.
7. Insert valve into engine brake body and temporarily tighten engine brake body using one bolt. Install lubricating nozzle into case and connect lubrication pipe. Install bracket and temporarily tighten bolt. Install engine brake pipe, ensuring pipe is inserted into hole in side case.
8. Install parking rod on shift cam. Ensure rod faces correct direction. While inserting fork pin in groove in shift cam, position parking rod in hole on parking cam guide. Pass shift arm through transmission case and shift cam. Insert roll pin into case. Install engine brake cam on shift arm with snap ring and roll pin. Secure shift arm to shift cam using roll pin.
9. Install differential assembly into case. Measure distance "h" between mating surface of transmission case and Gauge (499575660) top surface using depth gauge. Measure distance "H" between mating surface of clutch housing and gauge top surface using depth gauge. See Fig 2.
   Fig 2: Measuring Differential Thrust Clearance

   Courtesy of SUBARU OF AMERICA, INC.
10. Using equation C=H - h, calculate thrust clearance. Select number of suitable washers. See THRUST CLEARANCE WASHER  SPECIFICATION table. Install selected number of washers onto differential assembly.
    THRUST CLEARANCE WASHER SPECIFICATION
    
    

    Clearance "C" In. (mm)	No. Of Washers
    .008 (.20) Maximum	None
    .008 (.20) Minimum	1
    .016 (.40) Maximum	1
    .016 (.40) Minimum	2

11. On 4WD model, install transfer apply pipe and actuator body assembly. Clean mating surfaces of clutch housing and transmission case. Apply assembly lubricant to needle bearing and sealant to mating surfaces. On all models, install washer to clutch housing using assembly lube and install clutch housing to transmission case.
12. Tighten bolts in sequence. See Fig 3. Set select lever to "P" and ensure main drive shaft locks properly. On 4WD model, install washer, transfer driven gear, coupling, synchro transfer hub and sleeve with fork assembly. Install .055" (1.40 mm) snap ring and measure side clearance. Select snap ring to obtain clearance of .002-.012" (.05-.30 mm). See TRANSFER DRIVEN GEAR SNAP RING SPECIFICATION  table.
    TRANSFER DRIVEN GEAR SNAP RING SPECIFICATION
    
    

    Part No.	Thickness - In. (mm)
    805026031	.055 (1.40)
    805026032	.065 (1.65)
    805026033	.075 (1.90)

    Fig 3: Clutch Housing Tightening Sequence

    Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Clutch Housing Tightening Sequence

    Courtesy of SUBARU OF AMERICA, INC.
13. Install ball and spring into plug mounting hole and install plug with aluminum gasket. Install transfer cover. Install transfer solenoid rod with spring pin side facing solenoid valve and solenoid valve.
14. On all models, install Control Valve Holder (499205600) on control valve body. Install control valve body onto side case. Ensure valve body pin is inserted into dowel hole and engine brake lever contacts ratio sensor bolt seating surface.
15. Temporarily tighten control valve body mounting bolts. On 4WD model, install transfer control pipe. Tighten control valve body mounting bolts to 73-82 INCH lbs. (2.9-3.9 N.m) Install modulator connecting rod to ratio sensor and snap ring. Install Modulator Plate (498255600) into position. Push modulator adjusting plate away from center of valve body and tighten bolt.
16. On all models, install cable to shift control lever. Ensure inner cable is routed along guide rib. Connect electrical connector and install to bracket clip. Install oil strainer and "O" ring. Install oil pan. Install shift connecting rod. Turn roll pin of pilot pipe counterclockwise until it contacts with wall. Install oil pump assembly and temporarily tighten bolts. Evenly tighten bolts and push "O" ring inside case.
17. Position oil pump by lightly tapping with a plastic hammer. Install oil pump shaft. Ensure spline engages with mating part. Remove stand. Install oil cooler inlet and outlet pipes. Install pitching stopper bracket. Install brush holder.