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Transfer Case and Extension Case Assembly: Installation

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  1. Install center differential and transfer driven gear into transfer case.
    Fig 1: Installing Center Differential And Transfer Driven Gear Into Transfer Case
    G02862895Courtesy of SUBARU OF AMERICA, INC.
  2. Remove bearing cone from the extension case assembly, and install to taper roller bearing of the transfer driven gear.
    Fig 2: Removing Bearing Cone From Extension Case Assembly
    G02862896Courtesy of SUBARU OF AMERICA, INC.
  3. While pressing the bearing cone horizontally, turn the driven shaft ten rotations.
  4. Measure height "W" between transfer case and taper roller bearing on the transfer driven gear.
    Fig 3: Measuring Height Between Transfer Case And Taper Roller Bearing On Transfer Driven Gear
    G02862897Courtesy of SUBARU OF AMERICA, INC.
  5. Measure depth "X".
    NOTE: Measure with bearing cone and thrust washer removed.
    Fig 4: Measuring Depth Of Bearing Cone
    G02862898Courtesy of SUBARU OF AMERICA, INC.
  6. Calculate space "t" using the following equation: t = X - W + 0.2-0.3 mm (0.008-0.012 in)
  7. Select nearest washer in the following table:

    Standard clearance between thrust washer and taper roller bearing:  0.2-0.3 mm T (0.008-0.012 in T)

    NOTE: T:  Tight
    TRANSFER CASE THRUST WASHER (50 x 61 x t) THICKNESS SPECIFICATIONS

    Part No. Thickness mm (in)
    803050060 0.50 (0.0197)
    803050061 0.55 (0.0217)
    803050062 0.60 (0.0236)
    803050063 0.65 (0.0256)
    803050064 0.70 (0.0276)
    803050065 0.75 (0.0295)
    803050066 0.80 (0.0315)
    803050067 0.85 (0.0335)
    803050068 0.90 (0.0354)
    803050069 0.95 (0.0374)
    803050070 1.00 (0.0394)
    803050071 1.05 (0.0413)
    803050072 1.10 (0.0433)
    803050073 1.15 (0.0453)
    803050074 1.20 (0.0472)
    803050075 1.25 (0.0492)
    803050076 1.30 (0.0512)
    803050077 1.35 (0.0531)
    803050078 1.40 (0.0551)
    803050079 1.45 (0.0571)
  8. Fit thrust washers into extension case.
  9. Install bearing cone into extension case.
  10. Measure depth "S" between transfer case and center differential.

    ST 398643600:  GAUGE

    Fig 5: Measure Depth Between Transfer Case And Center Differential
    G02862899Courtesy of SUBARU OF AMERICA, INC.
  11. Measure depth "T" between extension case and transfer drive gear.

    ST 398643600:  GAUGE

    Fig 6: Measure Depth Between Extension Case And Transfer Drive Gear
    G02862900Courtesy of SUBARU OF AMERICA, INC.
  12. Calculate space "U" using the following equation: U = S - T
  13. Select suitable washer in the following table:

    Standard clearance:  0.15-0.35 mm (0.0059-0.0138 in)

    EXTENSION CASE THRUST WASHER THICKNESS SPECIFICATIONS

    Part No. Thickness mm (in)
    803036050 0.9 (0.035)
    803036054 1.0 (0.039)
    803036051 1.1 (0.043)
    803036055 1.2 (0.047)
    803036052 1.3 (0.051)
    803036056 1.4(0.055)
    803036053 1.5 (0.059)
    803036057 1.6 (0.063)
    803036058 1.7 (0.067)
  14. Fit thrust washer on center differential.
  15. Apply proper amount of liquid gasket to the transfer case mating surface.

    Liquid gasket:  THREE BOND 1215B

    Fig 7: Applying Proper Amount Of Liquid Gasket To Transfer Case Mating Surface
    G02862901Courtesy of SUBARU OF AMERICA, INC.
  16. Install extension assembly into transfer case.

    Tightening torque:  40 N.m (4.1 kgf-m, 29.7 ft-lb)

    Fig 8: Installing Extension Assembly Into Transfer Case
    G02862902Courtesy of SUBARU OF AMERICA, INC.
  17. Install shifter arm to transfer case.
    Fig 9: Installing Shifter Arm To Transfer Case
    G02862903Courtesy of SUBARU OF AMERICA, INC.
  18. Hang the shifter arm on the 3rd-4th fork rod.
    Fig 10: Hanging Shifter Arm On 3rd-4th Fork Rod
    G02862904Courtesy of SUBARU OF AMERICA, INC.
  19. Install transfer case with extension case assembly to transmission case.

    Tightening torque:  25 N.m (2.5 kgf-m, 18.1 ft-lb)

    Fig 11: Installing Transfer Case With Extension Case Assembly To Transmission Case
    G02862905Courtesy of SUBARU OF AMERICA, INC.
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