Subaru IMPREZA GD 2007 Series Manual page 2863

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Transfer Case and Extension Case Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
7) Select the washer with the nearest value in the
following table.
Taper roller bearing preload
(standard protrusion) :
0.15 — 0.20 mm (0.006 — 0.008 in)
NOTE:
Always adjust to the specified range of preload.
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 the thrust washers on the transfer drive shaft.
9) Install the bearing outer race into the extension
case.
10) Measure the depth "S" between transfer case
and center differential.
ST 398643600 GAUGE
ST
11) Measure the depth "T" between extension case
and transfer drive gear.
ST 398643600
Thickness mm (in)
0.50 (0.0197)
0.55 (0.0217)
0.60 (0.0236)
0.65 (0.0256) NOTE:
ST thickness [15 mm (0.59 in)]
0.70 (0.0276)
12) Calculate the thrust washer "U" using the fol-
0.75 (0.0295)
lowing calculation:
0.80 (0.0315)
U = S + T – 30 mm (1.18 in) [Thickness of ST]
0.85 (0.0335)
13) Select a suitable washer in the following table.
0.90 (0.0354)
Standard clearance:
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)
14) Fit the thrust washer onto the center differen-
tial.
15) Apply a proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
S
MT-00122
5MT-40
GAUGE
ST
0.15 — 0.35 mm (0.0059 — 0.0138 in)
Thrust washer
Part No.
803036050
803036054
803036051
803036055
803036052
803036056
803036053
803036057
803036058
THREE BOND 1215 (Part No. 004403007) or
equivalent
T
MT-00123
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)
MT-00124