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.

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.

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 and the adjusting washer are removed.

Courtesy of SUBARU OF AMERICA, INC.
Calculate the adjusting washer thickness "T" using the following calculation.
T = X - W + (0.15-0.2 mm (0.006-0.008in))

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

0.15-0.20 mm (0.006-0.008in): Amount of standard protrusion

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

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

Preload of taper roller bearing (extension case side) (amount of standard protrusion):

0.15-0.20 mm (0.006-0.008in)

Adjusting 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 adjusting washer and taper roller bearing (extension case side) outer race.

Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "S" between transfer case + ST and center differential.
Special tool:

ST: 398643600 GAUGE

Courtesy of SUBARU OF AMERICA, INC.
Measure the height "T" between the extension case + ST and transfer drive gear.
Special tool:

ST: 398643600 GAUGE

Courtesy of SUBARU OF AMERICA, INC.
Calculate the adjusting washer thickness "U" using the following calculation.
U = S + T - 30 mm (1.18in) - (0.15-0.35 mm (0.0059-0.0138in))

S: Depth between transfer case + ST and center differential

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

30 mm (1.18in): ST thickness 15 mm (0.59in) x 2

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

Select a suitable adjusting washer in the following table.

Specification:

Clearance:

0.15-0.35 mm (0.0059-0.0138in)

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 liquid gasket seamlessly.
Liquid gasket:

THREE BOND 1215B or equivalent

Courtesy of SUBARU OF AMERICA, INC.
Install the extension case assembly.
Tightening torque:

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

Courtesy of SUBARU OF AMERICA, INC.
Replace the gasket with a new part, and temporarily install it to the transmission case side.

Install the transfer case together with the extension case assembly.

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.

Special tool:

ST: 18631AA000 HANDLE

Courtesy of SUBARU OF AMERICA, INC.

Set and hold the selector lever COMPL to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.

Courtesy of SUBARU OF AMERICA, INC.

Temporarily install the transfer case assembly.
Install the shift lever COMPL, then insert the remover or similar tool instead of straight pin.

Courtesy of SUBARU OF AMERICA, INC.
Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
Install the transfer case assembly.
Tightening torque:

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

Courtesy of SUBARU OF AMERICA, INC.
Install the shift lever COMPL and secure it with a new straight pin.

Courtesy of SUBARU OF AMERICA, INC.

Install the transfer cover.

Temporarily tighten the transfer cover mounting bolts.

Tighten bolts in order of (B), (A), (C), (D) to the specified torque.

Tightening torque:

15 N.m (1.5kgf-m, 11.1ft-lb)

Courtesy of SUBARU OF AMERICA, INC.

Apply liquid gasket seamlessly.
Liquid gasket:

THREE BOND 1215B or equivalent

Courtesy of SUBARU OF AMERICA, INC.
Install the transmission cover.
Tightening torque:

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

Courtesy of SUBARU OF AMERICA, INC.
Install the back-up light switch and the neutral position switch. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Switches and Harness>INSTALLATION .
Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Manual Transmission Assembly>INSTALLATION .