Transfer Case and Extension Case Assembly: Installation

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 And Extension Case
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Height Between Transfer Case And Taper Roller Bearing
Courtesy of SUBARU OF AMERICA, INC.
Measure depth "X" on bearing insertion part of the extension case.
NOTE: Measure with bearing outer race and thrust washer removed.

Fig 4: Measuring Bearing Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "t" 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 thrust washer to extension case.
Replace the bearing outer race attached to the transfer driven gear with the extension case.
Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth 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 6: Measuring Height Between Extension Case And Transfer Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Calculate the thrust washer thickness "U" 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)
803036080	1.8 (0.071)
803036081	1.9 (0.075)

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 7: Identifying Transfer Case Mating Surface
Courtesy of SUBARU OF AMERICA, INC.
Install the extension case assembly to the transfer case.
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.
Install the extension case assembly along with the transfer case to the transmission case.
1. Insert the axle shaft and hold, then move the HANDLE to align the spline position to install.
  ST 18631AA000 HANDLE
  
  Part No. 38415AA100 AXLE SHAFT
  
  Fig 9: Identifying Handle (ST 18631AA000)
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Push the transfer case assembly until the knock pin protrudes slightly from the transfer case.
  
  Fig 10: Identifying Transmission Case, Transfer Case And Knock Pin
  Courtesy of SUBARU OF AMERICA, INC.
2. Set and hold the selector lever to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.
  
  Fig 11: Holding Selector Lever To 1st-2nd Side
  Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the transfer case assembly.
Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.

Fig 12: Identifying Shift Lever Compl And Remover
Courtesy of SUBARU OF AMERICA, INC.
Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
Tighten the transfer case assembly to the specified torque.
Tightening torque:

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

Fig 13: Holding Selector Lever To 1st-2nd Side
Courtesy of SUBARU OF AMERICA, INC.
Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.
NOTE: Use new spring pin.

Fig 14: Identifying Shift Lever Compl And Remover
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission cover. Refer to Shift Link Assembly .