Transfer Case and Extension Case Assembly: Installation

Clean the mating surfaces of the transmission case, transfer case and extension case.
Apply a coat of grease to the taper roller bearing (transfer case side) of transfer driven gear and the roller rolling surface of the taper roller bearing (extension case side).
Grease:

NICHIMOLY N-130 or equivalent
Install the center differential and the transfer driven gear.

Fig 1: Installing Center Differential And Transfer Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Install the taper roller bearing (extension case side) outer race to the transfer driven gear.
While pressing the taper roller bearing (extension case side) outer race horizontally, rotate the transfer driven gear for ten turns.
Measure the height "W" between transfer case and taper roller bearing (transfer case side) on the transfer driven gear.

Fig 2: Measuring Height W Between Transfer Case And Taper Roller Bearing (Transfer Case Side) On Transfer Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "X" of taper roller bearing insertion part of the extension case.
NOTE: Measure while the taper roller bearing (extension case side) outer race, dish plate and adjusting washer are removed.

Fig 3: Measuring Depth X Of Taper Roller Bearing Insertion Part Of Extension Case
Courtesy of SUBARU OF AMERICA, INC.
Calculate the adjusting washer thickness "t" using the following calculation.
t = X - W - (1.715 - 1.765 mm (0.686 - 0.706 in)) X: Depth of taper roller bearing insertion part of extension case

W: Height between transfer case and taper roller bearing (transfer case side) on transfer driven gear

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

Adjusting washer (61 x 50 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 adjusting washer, dish plate and taper roller bearing (extension case side) outer race.
NOTE: Make sure the dish plate is installed in the proper direction.

Fig 4: Taper Roller Bearing (Extension Case Side) Outer Race, Dish Plate, Adjusting Washer And Extension Case
Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "S" between the transfer case + ST and the center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth "S" Between Transfer Case, Gauge (398643600) And Center Differential
Courtesy of SUBARU OF AMERICA, INC.
Measure the height "T" between the extension case + ST and the transfer drive gear.
ST 398643600 GAUGE

Fig 6: Measuring Height "T" Between Extension Case, Gauge (398643600) And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the adjusting washer thickness "U" using the following calculation.
U = S + T - 30 mm (1.18 in) - (0.15 - 0.35 mm (0.0059 - 0.0138 in))

S: Depth between the transfer case + ST and the center differential

T: Height between the extension case + ST and the transfer drive gear

30 mm (1.18 in): Thickness of ST (x 2 pieces)

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

Select a suitable adjusting washer in the following table.

Clearance:

0.15 - 0.35 mm (0.0059 - 0.0138 in)

Adjusting 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)

Install the adjusting washer to center differential.
Apply an appropriate amount of liquid gasket.
Liquid gasket:

THREE BOND 1215B or equivalent

Fig 7: Appropriate Amount Of Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Install the extension case assembly.
Tightening torque:

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

Fig 8: Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the shifter arm.
NOTE: Apply transmission gear oil to the oil seal lips.

Fig 9: Installing Shifter Arm
Courtesy of SUBARU OF AMERICA, INC.
Attach the gasket.
NOTE: Use a new gasket.
Hang the shifter arm on 3rd-4th fork rod.

Fig 10: Shifter Arm And 3rd-4th Fork Rod
Courtesy of SUBARU OF AMERICA, INC.
Install the transfer case together with the extension case assembly.
Tightening torque:

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

Fig 11: Transfer Case
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up light switch and the neutral position switch. Ref. to INSTALLATION , Switches and Harness.
Install the manual transmission assembly to the vehicle. Ref. to INSTALLATION , Manual Transmission Assembly.