Transfer Case And Extension Case Assembly - Subaru Legacy 2004 Service Manual

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MANUAL TRANSMISSION AND DIFFERENTIAL

9. Transfer Case and Extension

Case Assembly

1) Remove the manual transmission assembly

from vehicle. <Ref. to 5MT-31, REMOVAL, Manual

Transmission Assembly.>

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

sition switch. <Ref. to 5MT-41, 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

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 tight "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 preload between thrust washer and

taper roller bearing:

0.2 — 0.3 mm (0.008 — 0.012 in)

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