Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different variant/trim than selected.

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.

Fig 1: Installing Center Differential And 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.

Fig 2: Measuring Height Between Transfer Case And Taper Roller Bearing On 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.

Fig 3: Measuring Depth Of Taper Roller Bearing Insertion Part Of Extension Case
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 - 0.008 in))

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 - 0.008 in): Amount of standard protrusion

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

NOTE: 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 - 0.008 in)

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.

Fig 4: Installing Taper Roller Bearing (Extension Case Side) Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Measure the depth "S" between the transfer case + ST and the center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth S Between Transfer Case + ST And Center Differential
Courtesy of SUBARU OF AMERICA, INC.
Measure the height "T" between the extension case + ST and the transfer drive gear.
ST 398643600 GAUGE

Fig 6: Measuring Height T Between Extension Case + ST And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the adjusting washer thickness "U" using the following calculation.
U = S + T - 30 mm (1.18 in) - (0.15 - 0.35 mm (0.0059 - 0.0138 in))

S: Depth between the transfer case + ST and the center differential

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

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

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

Select a suitable adjusting washer in the following table.

Clearance:

0.15 - 0.35 mm (0.0059 - 0.0138 in)

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

Fig 7: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Install the extension case assembly.
Tightening torque:

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

Fig 8: Identifying Extension Case Assembly
Courtesy of SUBARU OF AMERICA, INC.
Temporarily install the gasket to the transmission case side.
NOTE: Use a new gasket.
Install the transfer case together with the extension case assembly.
1. 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.
  ST 18631AA000 HANDLE
  
  Fig 9: Moving Handle To Spline Position
  Courtesy of SUBARU OF AMERICA, INC.
2. 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.
  
  Fig 10: Holding Selector Lever COMPL
  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.

Fig 11: Installing Shift Lever COMPL
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:

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

Fig 12: Installing Transfer Case Assembly
Courtesy of SUBARU OF AMERICA, INC.
Secure the shift lever COMPL using a straight pin.
NOTE: Use a new straight pin.

Fig 13: Identifying Shift Lever COMPL And Straight Pin
Courtesy of SUBARU OF AMERICA, INC.
Install the transfer cover.
1. Temporarily install the transfer cover mounting bolts.
2. Tighten bolts in order of (B), (A), (C), (D).
  Tightening torque:
  
  15 N.m (1.5 kgf-m, 11.1 ft-lb)
  
  Fig 14: Transfer Cover Mounting Bolts Tightening Sequence
  Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket seamlessly.
Liquid gasket:

THREE BOND 1215B or equivalent

Fig 15: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission cover.
Tightening torque:

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

Fig 16: Identifying Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up light switch and the neutral switch. <Ref. to BACK-UP LIGHT AND NEUTRAL POSITION SWITCH , INSTALLATION, Switches and Harness.>
Install the manual transmission assembly to the vehicle. <Ref. to INSTALLATION , Manual Transmission Assembly.>