Transfer Case and Extension Case Assembly: Installation

WARNING: This page is about a different car, the 2021 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

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.

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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.

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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, dish plate and adjusting washer are removed.

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Calculate the adjusting washer thickness "T" using the following calculation.
T = X - W - (1.715 - 1.765 mm (0.686 - 0.706 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

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

Adjusting washer (61 x 50 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, dish plate and taper roller bearing (extension case side) outer race.
CAUTION: Pay attention to the orientation of the dish plate.

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Measure the depth "S" between the transfer case + ST and the center differential.
Preparation tool:

ST: GAUGE (398643600)

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Measure the height "T" between the extension case + ST and the transfer drive gear.
Preparation tool:

ST: GAUGE (398643600)

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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 (GAUGE) and the center differential

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

30 mm (1.18 in): Thickness of ST (GAUGE) 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.

Specification: 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 an appropriate amount of liquid gasket.
Liquid gasket:

THREE BOND 1215B or equivalent

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Install the extension case assembly.
Tightening torque:

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

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Install the shifter arm.
NOTE: Apply transmission gear oil to the oil seal lips.

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Install a new gasket.
Hook the shifter arm.

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Install the transfer case together with the extension case assembly.
Tightening torque:

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

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Install the back-up light switch and the neutral position switch. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (5MT)>SWITCHES AND HARNESS>INSTALLATION .
Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (5MT)> MANUAL TRANSMISSION ASSEMBLY>INSTALLATION .