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Transfer Case and Extension Case Assembly: Installation

  1. Install center differential and transfer driven gear into transfer case.
    Fig 1: Installing Center Differential & Transfer Driven Gear
    G02876379Courtesy 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
    G02876380Courtesy 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 "W" Between Transfer Case & Taper Roller Bearing
    G02876381Courtesy of SUBARU OF AMERICA, INC.
  5. Measure depth "X".
    NOTE: Measure with bearing cone and thrust washer removed.
    Fig 4: Measuring Depth With Bearing Cone & Thrust Washer
    G02876382Courtesy of SUBARU OF AMERICA, INC.
  6. Calculate space "t" using the following equation:
    1. t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
  7. Select nearest washer in the following table:
    1. Standard clearance between thrust washer and taper roller bearing:  0.2 - 0.3 mm (0.008 - 0.012 In)
    NOTE: Value of clearance must be within the specified range.
    THICKNESS SPECIFICATION

    Thrust washer (50 x 61 x t)
    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 on transfer drive shaft.
  9. Install bearing cone into extension case.
  10. Measure depth "S" between transfer case and center differential.
    1. ST 398643600 GAUGE
    Fig 5: Measuring Depth "S" Between Transfer Case & Center Differential
    G02876383Courtesy of SUBARU OF AMERICA, INC.
  11. Measure depth "T" between extension case and transfer drive gear.
    1. ST 398643600 GAUGE
    Fig 6: Measuring Depth "T" Between Extension Case & Transfer Drive Gear
    G02876384Courtesy of SUBARU OF AMERICA, INC.
  12. Calculate space "U" using the following equation:
    1. U = S + T-30mm (1.18 in) [Thickness of ST]
  13. Select suitable washer in the following table:
    1. Standard clearance:  0.15 - 0.35 mm (0.0059 - 0.0138 In)
    THICKNESS SPECIFICATION

    Thrust washer
    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.

    THREE BOND 12W (Part No. 004403007) 

    1. Liquid gasket: 
    Fig 7: Applying Proper Liquid Gasket To Transfer Case Mating Surface
    G02876385Courtesy of SUBARU OF AMERICA, INC.
  16. Install extension assembly into transfer case.
    1. Tightening torque:  40 N.m (4.1 kgf-m, 29.7 ft-lb)
    Fig 8: Installing Extension Assembly Into Transfer Case
    G02876386Courtesy of SUBARU OF AMERICA, INC.
  17. Install shifter arm to transfer case.
    Fig 9: Installing Shifter Arm To Transfer Case
    G02876387Courtesy 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
    G02876388Courtesy of SUBARU OF AMERICA, INC.
  19. Install 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 11: Installing Transfer Case
    G02876389Courtesy of SUBARU OF AMERICA, INC.
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