Transfer Clutch: Adjustment

Install the transfer clutch assembly to the extension case with the transfer driven gear shims and thrust bearings removed.

Fig 1: Identifying Transfer Clutch Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the thrust bearing to the transfer driven gear.
NOTE: Make sure to install in the right direction.

Fig 2: Identifying Thrust Bearing Installation Position
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, measure the height "A" from the ST end face to the thrust bearing catch surface of the transfer clutch assembly.
ST 499575500 GAUGE

Fig 3: Measuring Height "A" From ST End Face To Thrust Bearing Catch Surface Of Transfer Clutch Assembly Using Gauge
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, measure the height "B" from the transmission case mating surface to the end of ST.
ST 499575500 GAUGE

Fig 4: Measuring Height "B" From Transmission Case Mating Surface To End Of ST Using Gauge
Courtesy of SUBARU OF AMERICA, INC.

Obtain the thickness of transfer driven gear shim using the following formula to select one to three transfer driven gear shims.

T (mm) = A - B - (0.05 - 0.25)

[T (in) = A - B - (0.002 - 0.01)]

T: Transfer driven gear shim thickness

A: Height from the ST end face to the transfer clutch assembly thrust bearing catch surface

B: Height from the mating surface of the transmission case to the end of the ST

0.05 - 0.25 mm (0.002 - 0.01 in): Clearance