Transfer Case and Extension Case Assembly

The content of this article/image reflects the changes identified in tsb 18_99_06 Dated 01/19/06 and applies to Legacy, Forester, Impreza and Baja models.

Transfer Case and Extension Case Assembly

REMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Remove the back-up light switch and neutral position switch.





3. Remove the transfer case with extension case assembly.





4. Remove the shifter arm.
5. Remove the extension case assembly.

INSTALLATION





1. Install the center differential and transfer driven gear into transfer case.





2. Remove the bearing cone from bearing of the transfer driven gear.
3. While pressing the bearing cone horizontally, turn the driven shaft ten rotations.





4. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
5. Measure the depth "X".





NOTE: Measure with bearing cone and thrust washer removed.

6. Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 inch)
7. Select the nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing: 0.2 - 0.3 mm (0.008 - 0.012 inch)





NOTE: Set the clearance within standard clearance.

8. Fit the thrust washers on transfer drive shaft.
9. Install the bearing cone into extension case.





10. Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE





11. Measure the depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE

12. Loosen the retainer on the lower side by 3 notches and turn in the retainer on upper side by the same amount in order to obtain the backlash.
13. Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
14. Install temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.

NOTE:

Install the lock plate upside down if it is hard to install.

15. Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer.
16. Inspect and adjust the backlash and tooth contact of hypoid gear.
17. After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen the retainer until the 0-ring groove appears. Fit the 0- ring into groove and tighten the retainer to the original position. Install the lock plate.

NOTE:

^ Record how many times the retainer is turned while loosening.
^ Carry out this job on both upper and lower retainers.






Tightening torque:
25 N.m (2.5 kg f-rn, 18.1 ft. lbs.)

18. Selecting of main shaft rear plate.
19. Install the clutch release lever and bearing.
20. Install the transfer case with extension case assembly.
21. Install the manual transmission assembly into the vehicle.


DISASSEMBLY
TRANSFER CASE





1. Remove the reverse check assembly.
2. Remove the oil guide.

EXTENSION CASE
1. Remove the transfer drive gear assembly.





2. Remove the shift bracket.
3. Remove the oil seal from extension case.

ASSEMBLY
EXTENSION CASE
1. Using the ST, insert the new oil seal to extension case.





2. Install the shift bracket to extension case.
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.)
3. Install the transfer drive gear to extension case.

TRANSFER CASE





1. Install the oil guide to transfer case.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
2. Install the reverse check sleeve assembly to transfer case.