Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different car, the 2013 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Install the center differential and transfer driven gear into the transfer case.

Fig 1: Identifying Center Differential And Transfer Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Remove the bearing outer race and thrust washer from the extension case.

Fig 2: Identifying Bearing Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Install the bearing outer race to transfer driven gear.
While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
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 On Transfer Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Measure depth "X" of bearing insertion part of the extension case.
NOTE: Measure with bearing outer race and thrust washer removed.

Fig 4: Measuring Depth "X" Of Bearing Insertion Part Of Extension Case
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "t" mm (in) using the following calculation.
t = X - W + (0.15 - 0.20 mm (0.006 - 0.008 in))

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

Preload of the taper roller bearing (amount of standard protrusion):

0.15 - 0.20 mm (0.006 - 0.008 in)

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

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)

Install the selected thrust washer and bearing outer race into the extension case.

Fig 5: Bearing Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 6: Measuring Depth "S" Between Transfer Case And Center Differential
Courtesy of SUBARU OF AMERICA, INC.
Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 7: Measuring Height "T" Between Extension Case And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "U" mm (in) using the following calculation.
U = S + T - 30 mm (1.18 in) [Thickness of ST]

NOTE: Thickness of ST: 15 mm (0.59 in)

Select a suitable washer in the following table.

Standard clearance:

0.15 - 0.35 mm (0.0059 - 0.0138 in)

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)

Fit the thrust washer onto the center differential.
Apply a proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 8: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Attach the extension assembly to the transfer case.
Tightening torque:

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

Fig 9: Identifying Transfer Case Extension Assembly
Courtesy of SUBARU OF AMERICA, INC.
Attach the shifter arm to transfer case.

Fig 10: Attaching Shifter Arm To Transfer Case
Courtesy of SUBARU OF AMERICA, INC.
Attach the gasket.
NOTE: Use a new gasket.
Hang the shifter arm on 3rd-4th fork rod.

Fig 11: Identifying Shifter Arm And 3rd-4th Fork Rod
Courtesy of SUBARU OF AMERICA, INC.
Install the transfer case along with the extension case assembly to the transmission case.
Tightening torque:

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

Fig 12: Identifying Transfer Case With Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.