Extension Case: Disassembly

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.

MPT MODEL
1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.
  NOTE: Be careful not to damage the oil seal in the extension.
  
  Fig 1: Tapping End Of Rear Drive Shaft
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the transmission clutch pipe without bending pipe.
  
  Fig 2: Removing Transmission Clutch Pipe Without Bending Pipe
  Courtesy of SUBARU OF AMERICA, INC.
VTD MODEL
1. Remove snap ring using ST1, ST2, ST3 and a press.
  
  Fig 3: Removing Snap Ring Using ST1, ST2, ST3 & Press
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove test plug.
  
  Fig 4: Removing Test Plug
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove clutch piston using compressed air.
  
  Fig 5: Removing Clutch Piston Using Compressed Air
  Courtesy of SUBARU OF AMERICA, INC.
4. Pay attention, not to bend pipe, and remove transfer clutch pipe.
  
  Fig 6: Removing Transfer Clutch Pipe
  Courtesy of SUBARU OF AMERICA, INC.
5. Remove the dust cover from the extension case.
6. Remove the oil seal from the extension case.