Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different variant/trim than selected.

Install the center differential and transfer driven gear into transfer case.

Fig 1: Identifying Center Differential And Transfer Driven Gear
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Remove the bearing outer race from extension case.

Fig 2: Identifying Bearing Outer Race
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While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
Measure the 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
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Measure the depth "X".
NOTE: Measure with bearing cone and thrust washer removed.

Fig 4: Measuring Bearing Cone
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Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
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.

Fig 5: Thrust Washer Specification Chart
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Fit the thrust washers on transfer drive shaft.
Install the bearing cone into extension case.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 6: Measuring Depth Between Transfer Case And Center Differential
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Measure the depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 7: Measuring Depth Between Extension Case And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the space "U" using the following equation: U = S + T - 30 mm (1.18 in) [Thickness of ST]
Select the suitable washer in the following table:
1. Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 in)
Fig 8: Thrust Washer Reference Chart
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Fit the thrust washer on center differential.
Apply proper amount of liquid gasket to the transfer case mating surface.
1. Liquid gasket: THREE BOND 1215 (Part No.: 004403007)
Fig 9: Applying Liquid Gasket To Transfer Case Mating Surface
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Install the extension assembly into transfer case.
1. Tightening torque: 40 N.m (4.1 kgf-m, 29.7 ft-lb)
Fig 10: Identifying Extension Assembly
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Install the shifter arm to transfer case.

Fig 11: Identifying Shifter Arm
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Hang the shifter arm on 3rd-4th fork rod.

Fig 12: Hanging Shifter Arm On 3rd-4th Fork Rod
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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)
Fig 13: Identifying Transfer Case With Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.