Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

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

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

Fig 2: Identifying Bearing Outer Race And Extension Case
While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
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
Measure depth "X" on bearing insertion part of the extension case.
NOTE: Measure with bearing outer race and thrust washer removed.

Fig 4: Measuring Depth On Bearing Insertion Part Of Extension Case
Calculate the tight "t" using following equation, t = X - W + 0.2 - 0.3 mm (0.008 - 0.012 in)

Select the washer with the nearest value in the following table.

Amount of standard protrusion of the taper roller bearing outer race

0.2 - 0.3 mm (0.008 - 0.012 in)

NOTE: Be sure that the amount of protrusion is always within the standard.

THRUST WASHER THICKNESS SPECIFICATIONS

Thrust washer (50 x 61 x t)
Part number	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)

Fit the thrust washers on the transfer drive shaft.
Install the bearing outer race into the extension case.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth Between Transfer Case And Center Differential
Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 6: Measuring Depth Between Extension Case And Transfer Drive Gear

NOTE: ST thickness [15 mm (0.59 in)]
Calculate the space "U" using the following equation:
U = S + T - 30 mm (1.18 in) [Thickness of ST]

Select a suitable washer in the following table.

Standard clearance:

0.15 - 0.35 mm (0.0059 - 0.0138 in)

THRUST WASHER THICKNESS SPECIFICATIONS

Thrust washer
Part number	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)

Fit the thrust washer onto the center differential.
Apply a proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 7: Identifying Liquid Gasket On Transfer Case Mating Surface
Install the extension assembly into the transfer case.
Tightening torque:

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

Fig 8: Identifying Extension Assembly
Attach the shifter arm to transfer case.

Fig 9: Identifying Shifter Arm
Hang the shifter arm on 3rd-4th fork rod.

Fig 10: Identifying Shifter Arm On 3rd-4th Fork Rod
Install the extension case assembly along with the transfer case to the transmission case.
Tightening torque:

24.5 N.m (2.5 kgf-m, 18.1 ft-lb)

Fig 11: Identifying Transfer Case Assembly