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Transfer Clutch: Assembly

  1. Install the transfer clutch piston, return spring and transfer clutch piston seal.
    NOTE:
    • Apply CVTF to the seal section of transfer clutch piston.
    • Apply CVTF to the lip section of transfer clutch piston seal.
    G16342191Courtesy of SUBARU OF AMERICA, INC.
    (A) Transfer clutch piston seal
    (B) Return spring
    (C) Transfer clutch piston
    (D) Rear drive shaft
  2. Compress the return spring using the ST and a press to install the snap ring.

    Preparation tool: 

    ST: COMPRESSOR SPECIAL TOOL (18762AA001)

    G13936100Courtesy of SUBARU OF AMERICA, INC.
  3. Blow compressed air through the hole shown in the figure, and check the transfer clutch piston operation.
    G13936102Courtesy of SUBARU OF AMERICA, INC.
  4. Select the transfer clutch plate set and pressure plate (rear side).
    NOTE: The pressure plate (front side) is included in the transfer clutch plate set.
    1. Set the pressure plate (rear side) and transfer clutch plate set to the rear drive shaft, and then install the snap ring.
      NOTE: Face the smooth side of the pressure plate (rear side) toward the transfer clutch plate set.
      G16342194Courtesy of SUBARU OF AMERICA, INC.
      (A) Snap ring
      (B) Transfer clutch plate set
      (C) Pressure plate (front side)
      (D) Drive plate
      (E) Driven plate
      (F) Pressure plate (rear side)
      (G) Rear drive shaft
    2. Set the shim, etc. (A) between the snap ring and pressure plate (front side) so that each plate does not tilt.
      G13936107Courtesy of SUBARU OF AMERICA, INC.
    3. Measure the clearance "C" between the snap ring and pressure plate (front side) using a thickness gauge.

      Service limit: 

      1.45 mm (0.057 in)

      G16342840Courtesy of SUBARU OF AMERICA, INC.
      (A) Snap ring
      (B) Pressure plate (front side)
    4. If the value exceeds the limit, perform the following procedures.
      1. Measure the thickness of the pressure plate (front side) and pressure plate (rear side).
      2. Replace with a new transfer clutch plate set that includes a pressure plate (front side) whose thickness is close to the measured thickness of pressure plate (front side), and perform measurement from step  2 again.

        Initial standard: 

        0.7 - 1.1 mm (0.03 - 0.04 in)

      3. If it exceeds the initial standard value, adjust the thickness of pressure plate (rear side) so that the value falls within the initial standard.
  5. Press-fit a new ball bearing using ST1, ST2 and a press.
    NOTE: Apply CVTF to the press-fitting area.

    Preparation tool: 

    ST1: INSTALLER (398177700)

    ST2: EXTENSION DRIVE SHAFT (927130000)

    G08317917Courtesy of SUBARU OF AMERICA, INC.
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