Transfer Driven Gear Adjusting Washer Adjustment

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

Using the ST, remove the taper roller bearing (extension case side) outer race.
ST 18758AA000 PULLER

Fig 1: Removing Taper Roller Bearing (Extension Case Side) Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Remove the adjusting washer.
Measure depth "Z" between the extension case end area and the taper roller bearing (extension case side) contact area.
ST 398643600 GAUGE

NOTE: When measuring depth "Z", subtract the thickness of the ST [15 mm (0.59 in)] from the measured value.

Fig 2: Measuring Depth Between Extension Case End Area And Taper Roller Bearing (Extension Case Side) Contact Area
Courtesy of SUBARU OF AMERICA, INC.
Remove the transfer driven gear. < Ref. to REMOVAL , Transfer Driven Gear. >
Remove the center differential. < Ref. to REMOVAL , Center Differential. >
Remove the oil guides G and H.

Fig 3: Removing Oil Guides G And H
Courtesy of SUBARU OF AMERICA, INC.
Remove the snap ring and washer from the selector arm area.

Fig 4: Identifying Snap Ring And Washer
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Using an ST, remove the neutral set spring and support.
ST1 18756AA000 CLAW

ST2 399893600 PLIER

Fig 5: Removing Neutral Set Spring And Support
Courtesy of SUBARU OF AMERICA, INC.
Lift the striking rod, and remove the straight pin.

Fig 6: Lifting Striking Rod
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Remove the selector arm No. 2, shifter arm shaft, selector plunger, shift accent plunger and spring.

Fig 7: Removing Selector Arm No. 2, Shifter Arm Shaft, Selector Plunger And Spring
Courtesy of SUBARU OF AMERICA, INC.
Attach the taper roller bearing (extension case side) to the transfer driven gear.
Set the ST.
ST 18831AA000 GAUGE

Fig 8: Attaching Taper Roller Bearing (Extension Case Side) To Transfer Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Turn the transfer driven gear 10 or more times to seat the taper roller bearing properly.
Measure depth "Y" between the end of the ST and the taper roller bearing (extension case side).
ST 18831AA000 GAUGE

Fig 9: Measuring Depth Y Between End Of ST And Taper Roller Bearing (Extension Case Side)
Courtesy of SUBARU OF AMERICA, INC.

Using the following calculation, calculate the transfer driven gear adjusting washer value "t". t = Z - (100 - Y) - {0.02 - 0.11 mm (0.0008 - 0.0043 in)}

t mm (in)	Transfer driven gear adjusting washer thickness
Y mm (in)	Depth between the end of the ST and the taper roller bearing (extension case side)
Z mm (in)	Depth between the end of the Z extension case and the taper roller mm (in) bearing (extension case side) contact area
0.02 - 0.11 mm (0.0008 - 0.0043 in)	Standard clearance between the adjusting washer and the taper roller bearing (extension case side)
100 mm (3.94 in)	Height of ST

Refer to the calculated value "t" to select the closest adjusting washer from the following table.

Standard clearance between the adjusting washer and the taper roller bearing (extension case side)

0.02 - 0.11 mm (0.0008 - 0.0043 in)

NOTE: Match to be within the standard clearance range.

Adjusting washer (50 x 61 x t)
Part No.	Thickness t 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 (0.0570)

Install the selector arm No. 2, shifter arm shaft, selector plunger, shift accent plunger and spring.

Fig 10: Installing Selector Arm No. 2, Shift Accent Plunger And Spring
Courtesy of SUBARU OF AMERICA, INC.
Install a new straight pin
Using the ST, install the neutral set spring and support.
ST1 18756AA000 CLAW

ST2 399893600 PLIER

Fig 11: Installing Neutral Set Spring And Support
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap ring to the selector arm area.

Fig 12: Identifying Washer And Snap Ring
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Install the center differential. < Ref. to INSTALLATION , Center Differential. >