Transfer Case And Extension Case Assembly: Installation

WARNING: This page is about a different car, the 2001 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Install center differential and transfer driven gear into transfer case.

Fig 1: Installing Center Differential And Transfer Driven Gear Into Transfer Case
Measure height "W" between transfer case and ball bearing on the transfer driven gear.

Fig 2: Measuring Height "W"
Measure depth "X".

Fig 3: Measuring Depth "X"
Calculate space "Y" using the following equation: Y = X - W + 0.24 mm (0.0094 in) [Thickness of gasket].
Select suitable washer in the following table:
Standard clearance between thrust washer and ball bearing:
1. 0.05-0.30 mm (0.0020-0.0118 in)
Fig 4: Space "Y" Thrust Washer Chart
Fit thrust washers on transfer drive shaft.
Measure depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth "S"
Measure depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 6: Measuring Depth "T"
Calculate space "U" using the following equation: U = S + T - 0.24 mm (0.0094 in) [Thickness of gasket]
Select suitable washer in the following table:
Standard clearance:
1. 0.15-0.35 mm (0.0059-0.0138 in)
Fig 7: Thrust Washer Selection Chart
Fit thrust washer on center differential.
Install extension assembly into transfer case.
Tightening torque: 37 N.m (3.8 kgf-m, 27.5 ft-lb)

Fig 8: Installing Extension Assembly Into Transfer Case
Install shifter arm to transfer case.

Fig 9: Installing Shifter Arm To Transfer Case
Hang the shifter arm on the 3rd-4th fork rod.

Fig 10: Hanging Shifter Arm On 3rd-4th Fork Rod
Install transfer case with extension assembly to transmission case.
Tightening torque: 24.5 N.m (2.50 kgf-m, 18.1 ft-lb)

Fig 11: Installing Transfer Case With Extension Assembly To Transmission Case