Transfer Clutch: Assembly

WARNING: This page is about a different car, the 2001 Subaru Outback, 2001 Subaru Legacy, 2001 Subaru Impreza, and 2001 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Install the transfer clutch piston.

Fig 1: Installing Transfer Clutch Piston
Install return spring to transfer piston.

Fig 2: Installing Return Spring To Transfer Piston
Install transfer clutch piston seal.

Fig 3: Installing Transfer Clutch Piston Seal
Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE

Fig 4: Installing ST To Rear Drive Shaft
Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE

Fig 5: Installing Snap Ring To ST
Using ST1 and ST2, install snap ring to rear drive shaft.
NOTE: After installing snap ring, remove ST1 and ST2.

ST1 499257300 SNAP RING OUTER GUIDE

ST2 499247400 INSTALLER

Fig 6: Installing Snap Ring To Rear Drive Shaft
Install the driven plates, drive plates, pressure plate and snap ring.

Fig 7: Installing Plates & Snap Ring
Apply compressed air to see if the assembled parts move smoothly.

Fig 8: Checking Clutch Pack For Smooth Movement
Check the clearance.
NOTE:
- Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.
- If the clearance is not within specification, adjust it by selecting a suitable pressure plate on the transfer clutch piston side.
Standard value:
1. 0.7 - 1.1 mm (0.028 - 0.043 in)
Allowable limit:
1. 1.6 mm (0.063 in)
Fig 9: Measuring Clutch Pack Clearance

Fig 10: Pressure Plate Thickness Chart
Press-fit the ball bearing with ST.
ST 899580100 INSTALLER

Fig 11: Installing Ball Bearing
Coat the seal ring with vaseline, and install it in the seal ring groove of the shaft.
CAUTION: Do not expand the seal ring excessively when installing.

Fig 12: Installing Seal Ring
Install the transfer clutch assembly to the case.
CAUTION: Be careful not to damage the seal rings.

Fig 13: Installing Transfer Clutch Assembly