Transfer Case and Extension Case Assembly: Installation

Clean the mating surface of the extension case assembly and transfer case and the mating surface of transfer case and transmission cover.
Install the center differential and transfer driven gear into the transfer case.

Fig 1: Identifying Transfer Driven Gear And Center Differential
Courtesy of SUBARU OF AMERICA, INC.
Remove the bearing outer race from the extension case.

Fig 2: Identifying Bearing Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Install the bearing outer race to transfer driven gear.
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 "W" Between Transfer Case And Taper Roller Bearing
Courtesy of SUBARU OF AMERICA, INC.
Measure depth "X" of bearing insertion part of the extension case.
NOTE: Measure with bearing outer race and thrust washer removed.

Fig 4: Measuring Depth "X" Of Bearing Insertion Part Of Extension Case
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "t" using the following calculation.
t = X - W + (0.15 - 0.2 mm (0.006 - 0.008 in))

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

NOTE: Be sure that it is always within the preload.

Preload of the taper roller bearing (amount of standard protrusion):

0.15 - 0.20 mm (0.006 - 0.008 in)

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)

Install the selected thrust washer and bearing outer race to the extension case.

Fig 5: Identifying Bearing Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 6: Measuring Depth "S" Between Transfer Case And Center Differential Using Gauge
Courtesy of SUBARU OF AMERICA, INC.
Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 7: Measuring Height "T" Between Extension Case And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "U" using the following calculation.
U = S + T - 30 mm (1.18 in) - (0.15 - 0.35 mm (0.00590 - 0.0138 in))

S: Depth between transfer case and center differential

T: Depth between the extension case and transfer gear

30 mm (1.18 in): Thickness of ST

0.15 - 0.35 mm (0.0059 - 0.0138 in): Clearance

Select a suitable thrust washer in the following table.

Standard clearance:

0.15 - 0.35 mm (0.0059 - 0.0138 in)

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)
803036080	1.8 (0.071)
803036081	1.9 (0.075)

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

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 8: Identifying Liquid Gasket Applying Areas On Mating Surface Of Transfer Case
Courtesy of SUBARU OF AMERICA, INC.
Install the extension case assembly to the transfer case.
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)

Fig 9: Identifying Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.
Temporarily install the gasket to the transmission case side.
NOTE: Use a new gasket.
Install the extension case assembly along with the transfer case to the transmission case.
1. While moving the HANDLE to align the spline position, press in the transfer case assembly until the knock pin comes slightly out of transfer case.
  ST 18631AA000 HANDLE
  
  Fig 10: Installing Extension Case Assembly With Transfer Case To Transmission Case
  Courtesy of SUBARU OF AMERICA, INC.
2. Set and hold the selector lever to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.
  
  Fig 11: Removing Transfer Case And Extension Case Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the transfer case assembly.
Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.

Fig 12: Inserting Remover In Shift Lever COMPL
Courtesy of SUBARU OF AMERICA, INC.
Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
Tighten the transfer case assembly to the specified torque.
Tightening torque:

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

Fig 13: Identifying Transfer Case Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.
NOTE: Use new spring pin.

Fig 14: Identifying Shift Lever COMPL And Spring Pin
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket seamlessly to the mating surface of transmission cover.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 15: Identifying Liquid Gasket Applying Areas On Mating Surface Of Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission cover to transfer case.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 16: Identifying Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.