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Transfer Case And Extension Case Assembly: Installation

  1. Install the center differential and transfer driven gear into the transfer case.
    Fig 1: Identifying Center Differential And Transfer Driven Gear
    G05003002Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the bearing outer race from the extension case.
    Fig 2: Identifying Bearing Outer Race And Extension Case
    G06337995Courtesy of SUBARU OF AMERICA, INC.
  3. While holding the bearing outer race horizontally, rotate the driven shaft for ten turns.
  4. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
    Fig 3: Measuring Height "W" Between Transfer Case And Taper Roller Bearing
    G06337996Courtesy of SUBARU OF AMERICA, INC.
  5. 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 "X" On Bearing Insertion Part Of Extension Case
    G06337997Courtesy of SUBARU OF AMERICA, INC.
  6. Calculate the thrust washer thickness "t" using the following calculation.

    t = X - W + (0.15 - 0.25 mm (0.006 - 0.010 in))

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

    Preload (standard protrusion) of the taper roller bearing: 

    0.15 - 0.25 mm (0.006 - 0.010 in) 

    NOTE: Be sure that the preload is always within the standard.
    THRUST WASHER 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)
  8. Fit the thrust washers on the transfer drive shaft.
  9. Install the bearing outer race into the extension case.
  10. Measure the depth "S" between transfer case and center differential.

    ST 398643600 GAUGE

    Fig 5: Measuring Depth "S" Between Transfer Case And Center Differential
    G06337998Courtesy of SUBARU OF AMERICA, INC.
  11. Measure the height "T" between the extension case and transfer drive gear.

    ST 398643600 GAUGE

    Fig 6: Measuring Height "T" Between Extension Case And Transfer Drive Gear
    G06337999Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Thickness of ST: 15 mm (0.59 in)
  12. Calculate the thrust washer thickness "U" using the following calculation.

    U = S + T - 30 mm (1.18 in) [Thickness of ST]

  13. Select a suitable washer in the following table.

    Standard clearance: 

    0.15 - 0.35 mm (0.0059 - 0.0138 in) 

    THRUST WASHER 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)
    803036080 1.8 (0.071)
    803036081 1.9 (0.075)
  14. Fit the thrust washer onto the center differential.
  15. 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: Applying Amount Of Liquid Gasket To Transfer Case Mating Surface
    G05003008Courtesy of SUBARU OF AMERICA, INC.
  16. Install the extension assembly into the transfer case.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 8: Identifying Extension Case Assembly
    G05003001Courtesy of SUBARU OF AMERICA, INC.
  17. Attach the shifter arm to transfer case.
    Fig 9: Attaching Shifter Arm To Transfer Case
    G05003010Courtesy of SUBARU OF AMERICA, INC.
  18. Hang the shifter arm on 3rd-4th fork rod.
    Fig 10: Identifying Shifter Arm And 3rd-4th Fork Rod
    G06338003Courtesy of SUBARU OF AMERICA, INC.
  19. 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 Extension Case Assembly
    G05003000Courtesy of SUBARU OF AMERICA, INC.
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