Transfer Case and Extension Case Assembly: Installation

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 center differential and transfer driven gear into transfer case.

Fig 1: Installing Center Differential & Transfer Driven Gear Into Transfer Case
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Remove the bearing outer race from the extension case.

Fig 2: Removing Bearing Outer Race From Extension Case
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While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.

Fig 3: Measuring Height "W" Between Transfer Case & Taper Roller Bearing On Transfer Driven Gear
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Measure the depth "X".
NOTE: Measure with bearing cone and thrust washer removed.

Fig 4: Measuring Depth "X"
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Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
Select the nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing:
1. 0.2 - 0.3 mm (0.008 - 0.012 in)
NOTE: Be sure to keep the clearance within specifications.

Fig 5: Thrust Washers Specification Chart
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Fit the thrust washers on transfer drive shaft.
Install the bearing cone into extension case.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 6: Measuring Depth "S" Between Transfer Case & Center Differential
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Measure the depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 7: Measuring Depth "T" Between Extension Case & Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the space "U" using the following equation: U = S + T - 30 mm (1.18 in) [Thickness of ST]
Select the suitable washer in the following table:
1. Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 in)
Fig 8: Thrust Washer Specification Table
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Fit the thrust washer on center differential.
Apply proper amount of liquid gasket to the transfer case mating surface.
1. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
Fig 9: Applying Proper Amount Of Liquid Gasket To Transfer Case Mating Surface
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Install the extension assembly into transfer case.
1. Tightening torque: 40 N.m (4.1 kgf-m, 29.7 ft-lb)
Fig 10: Installing Extension Assembly Into Transfer Case
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Install the shifter arm to transfer case.

Fig 11: Installing Shifter Arm To Transfer Case
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Hang the shifter arm on 3rd-4th fork rod.

Fig 12: Hanging Shifter Arm On 3rd-4th Fork Rod
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Install the transfer case with extension case assembly to transmission case.
1. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 13: Installing Transfer Case With Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.