Transfer Case And Extension Case Assembly - Subaru Legacy 2005 Service Manual

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9. Transfer Case and Extension

Case Assembly

1) Remove the manual transmission assembly

from vehicle. <Ref. to 5MT-30, REMOVAL, Manual

Transmission Assembly.>

2) Remove the back-up light switch and neutral po-

sition switch. <Ref. to 5MT-40, REMOVAL, Switch-

es and Harness.>

3) Remove the transfer case with extension case

4) Remove the shifter arm.

5) Remove the extension case assembly.

B: INSTALLATION

1) Install the center differential and transfer driven

gear into transfer case.

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

2) Remove the bearing outer race from extension

(A) Bearing outer race

(B) Extension case

3) While pressing the bearing outer race horizontal-

ly, 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" on bearing insertion part

of extension case.

Measure with bearing outer race and thrust washer

6) Calculate the thickness of thrust washer "t" using

following equation.

t = X − W + 0.2 to 0.3 mm (0.008 to 0.012 in)

7) Select the washer of nearest value in the follow-

Standard protrusion amount of taper roller

bearing outer race:

0.2 — 0.3 mm (0.008 — 0.012 in)

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