Transfer Clutch: Assembly

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. 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
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Install return spring to transfer piston.

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

Fig 3: Installing Transfer Clutch Piston Seal
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Install ST to rear drive shaft.
1. ST 499257300 SNAP RING OUTER GUIDE
Fig 4: Installing ST To Rear Drive Shaft
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Install snap ring to ST.

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

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

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

Fig 8: Applying Compressed Air
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Check clearance between snap ring and pressure plate. Refer to INSPECTION .
Press-fit a new ball bearing with ST.

Fig 9: Pressing Ball Bearing Using Special Tool
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Coat a new seal ring with vaseline, and install it in the seal ring groove of the shaft.
NOTE: Do not expand the seal ring excessively when installing.

Fig 10: Installing Seal Ring In Seal Ring Groove Of Shaft
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Install the transfer clutch assembly without damaging seal ring.

Fig 11: Installing Transfer Clutch Assembly
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