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Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the center differential and transfer driven gear into transfer case.
    2. Fig 1: Installing Center Differential & Transfer Driven Gear Into Transfer Case
    G02093638Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the bearing cone from bearing of the transfer driven gear.
    3. Fig 2: Removing Bearing Cone From Bearing Of Transfer Driven Gear
    G02093639Courtesy of SUBARU OF AMERICA, INC.
  3. While pressing the bearing cone horizontally, turn the driven shaft ten rotations.
  4. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
    5. Fig 3: Measuring Height "W" Between Transfer Case & Taper Roller Bearing
    G02093640Courtesy of SUBARU OF AMERICA, INC.
  5. Measure the depth "X".
    NOTE: Measure with bearing cone and thrust washer removed.
    6. Fig 4: Measuring Depth "X"
    G02093641Courtesy of SUBARU OF AMERICA, INC.
  6. Calculate the space "t" using the following equation:
    1. t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
  7. Select the 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: Set the clearance within standard clearance.
    8. Fig 5: Thrust Washer Specifications Chart
    G02093642Courtesy of SUBARU OF AMERICA, INC.
  8. Fit the thrust washers on transfer drive shaft.
  9. Install the bearing cone into extension case.
  10. Measure the depth "S" between transfer case and center differential.

    ST 398643600 GAUGE

    11. Fig 6: Measuring Depth "S" Between Transfer Case & Center Differential
    G02093643Courtesy of SUBARU OF AMERICA, INC.
  11. Measure the depth "T" between extension case and transfer drive gear.

    ST 398643600 GAUGE

    12. Fig 7: Measuring Depth "T" Between Extension Case & Transfer Drive Gear
    G02093644Courtesy of SUBARU OF AMERICA, INC.
  12. Calculate the space "U" using the following equation:
    1. U = S + T - 30 mm (1.18 in) [Thickness of ST]
  13. Select the suitable washer in the following table:
    1. Standard clearance:  0.15 - 0.35 mm (0.0059 - 0.0138 in)
    14. Fig 8: Thrust Washer Specifications Chart
    G02093645Courtesy of SUBARU OF AMERICA, INC.
  14. Fit the thrust washer on center differential.
  15. Apply proper amount of liquid gasket to the transfer case mating surface.
    1. Liquid gasket:  THREE BOND 1215 (Part No.: 004403007)
    16. Fig 9: Applying Proper Amount Of Liquid Gasket To Transfer Case Mating Surface
    G02093646Courtesy of SUBARU OF AMERICA, INC.
  16. Install the extension assembly into transfer case.
    1. Tightening torque:  40 N.m (4.1 kgf-m, 29.7 ft-lb)
    17. Fig 10: Installing Extension Assembly Into Transfer Case
    G02093647Courtesy of SUBARU OF AMERICA, INC.
  17. Install the shifter arm to transfer case.
    18. Fig 11: Installing Shifter Arm To Transfer Case
    G02093648Courtesy of SUBARU OF AMERICA, INC.
  18. Hang the shifter arm on 3rd-4th fork rod.
    19. Fig 12: Hanging Shifter Arm On 3rd-4th Fork Rod
    G02093649Courtesy of SUBARU OF AMERICA, INC.
  19. 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)
    20. Fig 13: Installing Transfer Case With Extension Case Assembly To Transmission Case
    G02093650Courtesy of SUBARU OF AMERICA, INC.
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