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Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the center differential and transfer driven gear into transfer case.
    Fig 1: Identifying Center Differential And Transfer Driven Gear
    G05003002Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the bearing outer race from the extension case.
    Fig 2: Identifying Bearing Outer Race And Extension Case
    G04990895Courtesy of SUBARU OF AMERICA, INC.
  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 Between Transfer Case And Taper Roller Bearing On Transfer Driven Gear
    G05003004Courtesy of SUBARU OF AMERICA, INC.
  5. Measure the depth "X".
    NOTE: Measure with bearing cone and thrust washer removed.
    Fig 4: Measuring Depth X
    G05003005Courtesy of SUBARU OF AMERICA, INC.
  6. Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
  7. Select the nearest washer in the following table:

    Standard clearance between thrust washer and taper roller bearing: 

    0.2 - 0.3 mm (0.008 - 0.012 in) 

    NOTE: Be sure to keep the clearance within specifications.
    THRUST WASHER THICKNESS SPECIFICATIONS

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

    ST 398643600 GAUGE

    Fig 5: Measuring Depth Between Transfer Case And Center Differential Using ST398643600
    G05003006Courtesy of SUBARU OF AMERICA, INC.
  11. Measure the depth "T" between extension case and transfer drive gear.

    ST 398643600 GAUGE

    Fig 6: Measuring Depth Between Extension Case And Transfer Drive Gear Using ST398643600
    G05003007Courtesy of SUBARU OF AMERICA, INC.
  12. Calculate the space "U" using the following equation: U = S + T - 30 mm (1.18 in) [Thickness of ST]
  13. Select the suitable washer in the following table:

    Standard clearance: 

    0.15 - 0.35 mm (0.0059 - 0.0138 in) 

    THRUST WASHER THICKNESS SPECIFICATIONS

    Thrust 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)
  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: Identifying Liquid Gasket On Transfer Case Mating Surface
    G04990900Courtesy 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: Identifying Extension Case Assembly
    G05003001Courtesy of SUBARU OF AMERICA, INC.
  17. Install the shifter arm to transfer case.
    Fig 9: Identifying Shifter Arm
    G05003010Courtesy of SUBARU OF AMERICA, INC.
  18. Hang the shifter arm on 3rd-4th fork rod.
    Fig 10: Identifying Shifter Arm On 3rd-4th Fork Rod
    G04990903Courtesy of SUBARU OF AMERICA, INC.
  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: Identifying Transfer Case Assembly
    G05003000Courtesy of SUBARU OF AMERICA, INC.
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