Shift Link Assembly: Installation

Install the plunger and check ball spring to transmission cover.
NOTE: Use a new seal ring.

Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 1: Identifying Plunger And Check Ball Spring With Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing to the transfer case.
NOTE:
- Use the round bar with diameter of 20 - 21 mm (0.79 - 0.83 in).
- Press in by pushing the flange surface (stamp mark side).
Press-fit depth of needle bearing:

A: -8.5 mm (-0.33 in) from the end of transfer case

B: -0.2 mm (-0.01 in) from the end of transfer case

Fig 2: Identifying Needle Bearing Diameter
Courtesy of SUBARU OF AMERICA, INC.
Install the roll bearing to the transfer case.
NOTE: Use the round bar with diameter of 22 - 23 mm (0.87 - 0.91 in).

Press-fit depth of roll bearing:

A: 5.1 mm (0.20 in) from the finished surface of transfer case

B: Align with the end of transfer case.

Fig 3: Identifying Roll Bearing Diameter
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the oil seal to the transfer case.
NOTE:
- Use a new oil seal.
- The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
- Apply transmission gear oil to the oil seal lips.
Press-fit depth of oil seal:

-1.0 mm (-0.04 in) from the end of transfer case

ST 18657AA000 INSTALLER

Fig 4: Installing Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Insert the shifter arm into selector arm, then fix with a spring pin using the ST.
NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

Fig 5: Inserting Shifter Arm Into Selector Arm
Courtesy of SUBARU OF AMERICA, INC.
Install the shifter arm No. 2, washers and thrust bearing to transfer case.

Fig 6: Identifying Shifter Arm No. 2, Washers And Thrust Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the shifter arm collar and neutral set spring to transfer case.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 7: Identifying Shifter Arm Collar
Courtesy of SUBARU OF AMERICA, INC.
Install the selector arm No. 2 to neutral set spring.

Fig 8: Identifying Selector Arm No. 2 And Neutral Set Spring
Courtesy of SUBARU OF AMERICA, INC.
Insert the selector lever COMPL into selector arm No. 2, then fix with a spring pin using the ST.
NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

Fig 9: Identifying Selector Lever COMPL And Selector Arm No. 2
Courtesy of SUBARU OF AMERICA, INC.
Insert a new straight pin.

Fig 10: Identifying Selector Lever COMPL And Straight Pin
Courtesy of SUBARU OF AMERICA, INC.
Apply a proper amount of liquid gasket to the transmission cover mating surface.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 11: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission cover to transfer case.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 12: Identifying Transmission Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the extension assembly to the transfer case. Ref. to INSTALLATION , Transfer Case and Extension Case Assembly.
Install the transfer case and the extension case assembly. Ref. to INSTALLATION , Transfer Case and Extension Case Assembly.
Install the back-up light switch neutral position switch. Ref. to INSTALLATION , Switches and Harness.
Install the manual transmission assembly to the vehicle. Ref. to INSTALLATION , Manual Transmission Assembly.