Transfer Case & Extension Housing Reassembly

Install center differential and transfer drive shaft into transfer case. See Fig 1.

Measure center differential height "A". Measure transfer drive shaft depth "B". See Fig 2. Calculate distance "C" using equation C = B - A + .0094" (.240 mm) - .110" (2.80 mm). Select and install appropriate center differential washer. See CENTER DIFFERENTIAL WASHER table.

CENTER DIFFERENTIAL WASHER

Distance "C" In. (mm)	Part No.	Thickness In. (mm)
.0630-.0685 (1.600-1.740)	8965AA030	.050 (1.25)
.0689-.0744 (1.750-1.890)	8965AA040	.055 (1.40)
.0748-.0803 (1.900-2.040)	8965AA050	.060 (1.55)
.0807-.0862 (2.050-2.190)	8965AA060	.067 (1.70)
.0866-.0945 (2.200-2.400)	8965AA070	.073 (1.85)

Measure transfer driven gear bearing height "W" and extension housing depth "X". See Fig 3. Calculate distance "Y" using equation: Y = X - W + .0094" (.240 mm). Select and install appropriate thrust washer. See THRUST WASHER .

Fig 1: Exploded View Of Transfer Case & Extension Housing

Courtesy of SUBARU OF AMERICA, INC.

Fig 2: Measuring Differential Case Height

Courtesy of SUBARU OF AMERICA, INC.

Fig 3: Determining Thrust Washer Thickness

Courtesy of SUBARU OF AMERICA, INC.

THRUST WASHER

Distance "Y" In. (mm)	Part No.	Thickness In. (mm)
.0217-.0311 (.550-.790)	803052021	.020 (.50)
.0315-.0409 (.800-1.040)	803052022	.030 (.75)
.0413-.0512 (1.050-1.300)	803052023	.040 (1.00)

Install thrust bearing with roller side toward thrust washer. Install extension housing. Tighten bolts to 25-30 ft. lbs. (34-40 N.m).