Transfer Case And Extension Case Assembly - Subaru Legacy 2002 Service Manual

TRANSFER CASE AND EXTENSION CASE ASSEMBLY

7) Select nearest washer in the following table:
Standard clearance between thrust washer
and taper roller bearing:
0.2 — 0.3 mm T (0.008 — 0.012 in T)
NOTE:
T: Tight
Thrust washer (50 × 61 × t)
Part No.
803050060
803050061
803050062
803050063
803050064
803050065
803050066
803050067
803050068
803050069
803050070
803050071
803050072
803050073
803050074
803050075
803050076
803050077
803050078
803050079
8) Fit thrust washers on transfer drive shaft.
9) Install bearing cone into extension case.
10) Measure depth "S" between transfer case and
center differential.
ST 398643600 GAUGE
Thickness mm (in)
0.50 (0.0197)
0.55 (0.0217)
0.60 (0.0236)
0.65 (0.0256)
0.70 (0.0276)
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
1.00 (0.0394)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
1.20 (0.0472)
1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0531)
1.40 (0.0551)
1.45 (0.0571)
B3M1407A
MT-45
Manual Transmission and Differential
11) Measure depth "T" between extension case
and transfer drive gear.
ST 398643600 GAUGE
12) Calculate space "U" using the following equa-
tion: U = S + T − 30 mm (1.18 in) [Thickness of ST]
13) Select suitable washer in the following table:
Standard clearance:
0.15 — 0.35 mm (0.0059 — 0.0138 in)
Thrust washer
Part No.
803036050
803036054
803036051
803036055
803036052
803036056
803036053
803036057
803036058
14) Fit thrust washer on center differential.
15) Apply proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215
B3M1395A
Thickness mm (in)
0.9 (0.035)
1.0 (0.039)
1.1 (0.043)
1.2 (0.047)
1.3 (0.051)
1.4 (0.055)
1.5 (0.059)
1.6 (0.063)
1.7 (0.067)
B3M2266