Transfer Clutch: Assembly

WARNING: This page is about a different car, the 2003 Subaru Impreza. 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
Courtesy of SUBARU OF AMERICA, INC.
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.
ST 499257300 SNAP RING OUTER GUIDE

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

Fig 5: Installing Snap Ring To ST
Courtesy of SUBARU OF AMERICA, INC.
Using ST1 and ST2, install snap ring to rear drive shaft.
ST1 499257300 SNAP RING OUTER GUIDE

ST2 499247400 INSTALLER

Fig 6: Installing Snap Ring To Rear Drive Shaft Using ST1 & ST2
Courtesy of SUBARU OF AMERICA, INC.
Install the driven plates, drive plates, pressure plate and snap ring.

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

Fig 8: Applying Compressed Air To See If Assembled Parts Move Smoothly
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Inspect clearance between snap ring and pressure plate. See INSPECTION , Transfer Clutch.
Press-fit a new ball bearing with ST.
ST 899580100 INSTALLER

Fig 9: Press-Fitting New Ball Bearing With ST
Courtesy of SUBARU OF AMERICA, INC.
Coat a new seal ring with petrolatum, 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
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Install the transfer clutch assembly without damaging seal ring.

Fig 11: Installing Transfer Clutch Assembly
Courtesy of SUBARU OF AMERICA, INC.