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Transfer Case and Extension Case Assembly: Installation

  1. Install the center differential and transfer driven gear into the transfer case.
    2. Fig 1: Center Differential And Transfer Driven Gear
    G07665969Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the bearing outer race from the extension case.
    Fig 2: Bearing Outer Race Of Extension Case
    G07665970Courtesy of SUBARU OF AMERICA, INC.
  3. Install the bearing outer race to transfer driven gear.
  4. While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
  5. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
    Fig 3: Measuring Height "W" Between Transfer Case And Taper Roller Bearing On Transfer Driven Gear
    G07665971Courtesy of SUBARU OF AMERICA, INC.
  6. Measure depth "X" on bearing insertion part of the extension case.
    NOTE: Measure with bearing outer race and thrust washer removed.
    Fig 4: Measuring Depth "X" On Bearing Insertion Part Of Extension Case
    G07665972Courtesy of SUBARU OF AMERICA, INC.
  7. Calculate the thrust washer thickness "t" mm (in) using the following calculation.

    t = X - W + (0.15 - 0.20 mm (0.006 - 0.008 in))

  8. 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.
    PARTS THICKNESS SPECIFICATION CHART

    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)
  9. Install the selected thrust washer and bearing outer race into the extension case.
    Fig 5: Bearing Outer Race
    G07665973Courtesy of SUBARU OF AMERICA, INC.
  10. Measure the depth "S" between transfer case and center differential.

    ST 398643600 GAUGE

    Fig 6: Measuring Depth "S" Between Transfer Case And Center Differential
    G07665974Courtesy of SUBARU OF AMERICA, INC.
  11. Measure the height "T" between the extension case and transfer drive gear.

    ST 398643600 GAUGE

    Fig 7: Measuring Height "T" Between Extension Case And Transfer Drive Gear
    G07665975Courtesy of SUBARU OF AMERICA, INC.
  12. Calculate the thrust washer thickness "U" mm (in) using the following calculation.

    U = S + T - 30 mm (1.18 in) [Thickness of ST]

    NOTE: Thickness of ST: 15 mm (0.59 in)
  13. Select a suitable washer in the following table.

    Standard clearance: 

    0.15 - 0.35 mm (0.0059 - 0.0138 in) 

    PARTS THICKNESS SPECIFICATION CHART

    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)
  14. Fit the thrust washer onto the center differential.
  15. Apply a proper amount of liquid gasket to the transfer case mating surface.

    Liquid gasket: 

    THREE BOND 1215 (Part No. 004403007) or equivalent 

    Fig 8: Proper Amount Of Liquid Gasket Applying Area On Transfer Case Mating Surface
    G07665976Courtesy of SUBARU OF AMERICA, INC.
  16. Attach the extension assembly to the transfer case.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 9: Extension Case Assembly
    G07665977Courtesy of SUBARU OF AMERICA, INC.
  17. Attach the shifter arm to transfer case.
    Fig 10: Attaching Shifter Arm To Transfer Case
    G07665978Courtesy of SUBARU OF AMERICA, INC.
  18. Hang the shifter arm on 3rd-4th fork rod.
    Fig 11: Shifter Arm And 3rd-4th Fork Rod
    G07665979Courtesy of SUBARU OF AMERICA, INC.
  19. Install the transfer case along with the extension case assembly to the transmission case.

    Tightening torque: 

    24.5 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 12: Transfer Case And Extension Case Assembly
    G07665980Courtesy of SUBARU OF AMERICA, INC.
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