Transfer Case and Extension Case Assembly: Installation

1. Install the center differential and transfer driven gear into transfer case.
   Fig 1: Installing Center Differential

   Courtesy of SUBARU OF AMERICA, INC.
2. Remove the bearing outer race from extension case.
   Fig 2: Removing Bearing Outer Race From Extension Case

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3. While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
4. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
   Fig 3: Measuring Height "W" Between Transfer Case And Taper Roller Bearing

   Courtesy of SUBARU OF AMERICA, INC.
5. Measure the depth "X" on bearing insertion part of extension case.
   NOTE: Measure with bearing outer race and thrust washer removed.
   Fig 4: Measuring Depth "X" On Bearing Insertion Part Of Extension Case

   Courtesy of SUBARU OF AMERICA, INC.
6. Calculate the tight "t" using following equation, t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
7. Select the washer of nearest value in the following table:

   Standard preload between thrust washer and taper roller bearing: 

   0.2 - 0.3 mm (0.008 - 0.012 in) 

   NOTE: Be sure that the preload is within standard value.
   PART NUMBER AND THICKNESS SPECIFICATION CHART
   
   

   Thrust washer (50 x 61 x t)
   Part Number	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)

8. Fit the thrust washers on transfer drive shaft.
9. Install the bearing outer race into extension case.
10. Measure the depth "S" between transfer case and center differential.

    ST 398643600 GAUGE

    Fig 5: Measuring Depth "S" Between Transfer Case And Center Differential

    Courtesy of SUBARU OF AMERICA, INC.
11. Measure the height "T" between extension case and transfer drive gear.

    ST 398643600 GAUGE

    Fig 6: Measuring Height "T" Between Extension Case And Transfer Drive Gear

    Courtesy of SUBARU OF AMERICA, INC.
12. Calculate the thrust washer "U" using following equation.

    U = {15 mm (1.18 in)-T}-{S-15 mm (1.18 in)}-

    0.15 to 0.35 mm (0.0059 to 0.0138 in)

    PART NUMBER AND THICKNESS SPECIFICATION CHART
    
    

    U mm (in)	Thickness of transfer drive gear thrust washer
    T mm (in)	Height from end of ST to transfer drive gear
    S mm (in)	Depth from end of transmission case to the end of ST
    0.15 - 0.35 mm (0.0059 - 0.0138 in)	Standard clearance between thrust washer and transfer drive gear.
    15 mm (1.18 in)	Thickness of ST

13. Select a suitable washer in the following table:

    Standard clearance: 

    0.15 - 0.35 mm (0.0059 - 0.0138 in) 

    PART NUMBER AND THICKNESS SPECIFICATION CHART
    
    

    Thrust washer
    Part Number	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)

14. Fit the thrust washer on center differential.
15. Apply proper amount of liquid gasket to the transfer case mating surface.

    Liquid gasket: 

    THREE BOND 1215 (Part No. 004403007) or equivalent 

    Fig 7: Applying Proper Amount Of Liquid Gasket To Transfer Case Mating Surface

    Courtesy of SUBARU OF AMERICA, INC.
16. Install the extension assembly into transfer case.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.7 ft-lb) 

    Fig 8: Installing Extension Assembly Into Transfer Case

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17. Install the shifter arm to transfer case.
    Fig 9: Installing Shifter Arm To Transfer Case

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18. Hang the shifter arm on 3rd-4th fork rod.
    Fig 10: Hanging Shifter Arm On 3rd-4th Fork Rod

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19. Install the transfer case with extension case assembly to transmission case.

Tightening torque: 

24.5 N.m (2.5 kgf-m, 18.1 ft-lb) 

Fig 11: Installing Transfer Case With Extension Case Assembly

Courtesy of SUBARU OF AMERICA, INC.