Shift Link Assembly: Installation

Clean the mating surface of the transmission cover and transfer case.
Install the plunger and check ball spring to transmission cover.
NOTE: Use a new seal ring.

Tightening torque:

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

Fig 1: Identifying Plunger, Checking Ball Spring, Transmission Cover, Seal Ring And Seal Bolt
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the needle bearing to the transfer case.
NOTE:
- Use a new needle bearing.
- If the press-fit depth exceeds the service limit, replace with a new needle bearing.
ST1 18763AA000 COMPRESSOR SHAFT

ST2 498277200 STOPPER SET

Press-fit depth of needle bearing:

A: 8.5±0.2 mm (0.33±0.01 in) from the end of transfer case

Fig 2: Installing Needle Bearing To Transfer Case Using Special Tools (Upto Press-Fit Depth)
Courtesy of SUBARU OF AMERICA, INC.

B: 0.2±0.2 mm (0.01±0.01 in) from the end of transfer case

Fig 3: Installing Needle Bearing To Transfer Case Using Special Tools (Upto Press-Fit Depth)
Courtesy of SUBARU OF AMERICA, INC.
Set ST1, ST2 and transfer case to a press.
NOTE:
- Set the ST2 under ST1.
- Set the transfer case so that the hole for shifter arm is positioned vertically.
ST1 498267300 CYLINDER HEAD TABLE

ST2 498267200 CYLINDER HEAD TABLE

Fig 4: Setting Special Tools And Transfer Case To Press
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the roller bearing to the transfer case.
NOTE:
- Use a new roller bearing.
- Gradually perform the press-fit operation while measuring the press-fit depth.
- If the press-fit depth exceeds the service limit, replace with a new bearing.
ST 899864100 REMOVER

Press-fit depth of roller bearing:

A: 5.1±0.2 mm (0.20±0.01 in) from the finished surface of transfer case

Fig 5: Installing Roller Bearing To Transfer Case Using Special Tool (Upto Press-Fit Depth)
Courtesy of SUBARU OF AMERICA, INC.
Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
- Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
- Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.
Using the ST, install the roller bearing to the transfer case.
NOTE:
- Use a new bearing.
- Gradually perform the press-fit operation while measuring the press-fit depth.
- If the press-fit depth exceeds the service limit, replace with a new bearing.
ST 899864100 REMOVER

Press-fit depth of roller bearing:

A: 0±0.2 mm (0±0.01 in) from the end of transfer case

Fig 6: Installing Roller Bearing To Transfer Case Using Special Tool (Upto Press-Fit Depth)
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the oil seal to the transfer case.
NOTE:
- Use a new oil seal.
- The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
- Apply transmission gear oil to the oil seal lips.
ST 18657AA000 INSTALLER

Press-fit depth of oil seal:

1±0.2 mm (0.04±0.01 in) from the end of transfer case

Fig 7: Installing Oil Seal To Transfer Case Using Special Tool (Upto Press-Fit Depth)
Courtesy of SUBARU OF AMERICA, INC.
Insert the shifter arm into the selector arm, and fix with a spring pin.
NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

Fig 8: Securing Shifter Arm In Selector Arm Using Spring Pin
Courtesy of SUBARU OF AMERICA, INC.
Install the shifter arm No. 2, washers and thrust bearing to transfer case.
CAUTION: Be careful not to damage the oil seal.

Fig 9: Identifying Shifter Arm No. 2, Washer And Thrust Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the shifter arm collar and neutral set spring to transfer case.
NOTE: Use a new gasket.

Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 10: Identifying Shifter Arm Collar And Neutral Set Spring
Courtesy of SUBARU OF AMERICA, INC.
Install the selector arm No. 2 to neutral set spring.

Fig 11: Identifying Selector Arm No. 2 And Neutral Set Spring
Courtesy of SUBARU OF AMERICA, INC.
Insert the selector lever COMPL into the selector arm No. 2, and fix with a spring pin.
CAUTION: Be careful not to damage the oil seal.

NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

Fig 12: Securing Selector Lever COMPL In Selector Arm No. 2 Using Spring Pin
Courtesy of SUBARU OF AMERICA, INC.
Insert a new straight pin.

Fig 13: Identifying Selector Lever COMPL And Straight 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 14: 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 15: Identifying Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the center differential and transfer driven gear as a unit.
Install the extension case assembly. Refer to INSTALLATION .
Attach the extension assembly to the transfer case. Refer to INSTALLATION .
Install the transfer case and the extension case assembly. Refer to INSTALLATION .
Install the back-up light switch and the neutral position switch. Refer to INSTALLATION .
Install the manual transmission assembly to the vehicle. Refer to INSTALLATION .