Subaru Outback (BR): Extension Case

A: REMOVAL

1) Remove the transmission assembly. <Ref. to 5AT-37, REMOVAL, Automatic Transmission Assembly.>

2) Disconnect the rear vehicle speed sensor connector.

3) Remove the rear vehicle speed sensor.

4) Remove the extension case.

B: INSTALLATION

1) Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline.

<Ref. to 5AT-72, ADJUSTMENT, Reduction Driven Gear.>

2) Install the extension case.

NOTE: Use a new gasket.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

3) Install the rear vehicle speed sensor.

NOTE: Use new O-rings.

Tightening torque: 7 N*m (0.7 kgf-m, 5.2 ft-lb)

4) Connect the rear vehicle speed sensor connector.

5) Install the transmission assembly. <Ref. to 5AT- 42, INSTALLATION, Automatic Transmission Assembly.>

C: DISASSEMBLY

1) Take out the transfer clutch and rear drive shaft by lightly tapping the end of rear drive shaft.

NOTE: Be careful not to damage the oil seal of the extension.

2) Remove the snap ring using the ST and press.

ST 18762AA000 COMPRESSOR SPECIAL TOOL

3) Supply compressed air to remove the clutch piston.

4) Remove the dust cover from extension case.

5) Remove the oil seal from the extension case.

D: ASSEMBLY

1) Press-fit the oil seal using the ST and press.

NOTE: Use a new oil seal.

ST 498057300 INSTALLER

2) Press-fit the dust cover.

3) Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.

1. Clutch spring retainer
2. Return spring
3. Spring retainer
4. Transfer clutch piston ASSY

4) Using the ST and compressor, install the snap ring.

ST 18762AA000 COMPRESSOR SPECIAL TOOL

5) Install the transfer clutch. <Ref. to 5AT-67, INSTALLATION, Transfer Clutch.>

6) Install the rear drive shaft.

E: INSPECTION

• Use compressed air to make sure the extension case routes are not clogged or leaking.
• Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-67, ADJUSTMENT, Transfer Clutch.>

Transfer Clutch

A: REMOVAL

1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-37, REMOVAL, Automatic Transmission Assembly.>

2) Remove the extension case, and then remove the transfer clutch. <Ref. to 5AT-65, REMOVAL, Extension Case.> <Ref. to 5AT-66, DISASSEMBLY, Extension Case.>

B: INSTALLATION

1) Select the rear drive shaft shim. <Ref. to 5AT-67, ADJUSTMENT, Transfer Clutch.>

2) Select driven plate No. 3 <Ref. to 5AT-67, ADJUSTMENT, Transfer Clutch.>

3) Install the extension case. <Ref. to 5AT-65, INSTALLATION, Extension Case.>

4) Install the transmission assembly to the vehicle.

<Ref. to 5AT-42, INSTALLATION, Automatic Transmission Assembly.>

C: INSPECTION

• Inspect the drive plate facing for wear and damage.
• Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
• Check that the D-ring is not damaged.
• Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-67, ADJUSTMENT, Transfer Clutch.>

D: ADJUSTMENT

1. REAR DRIVE SHAFT SHIM SELECTION

1) Insert the rear drive shaft into the reduction drive gear and center differential assembly.

2) Using the ST, measure the depth "A", which is from mating surface of extension case to ball bearing outer ring contact surface.

ST 398643600 GAUGE

3) Using the ST, measure the height "B" from the AT main case mating surface to the ball bearing outer ring contact surface.

ST 398643600 GAUGE

4) Calculation formula:

When clearances are 0.05 mm (0.0020 in):
T (mm) = A - B + 0.23
[T (in) = A - B + 0.0091]
When clearances are 0.25 mm (0.0098 in):
T (mm) = A - B + 0.03
[T (in) = A - B + 0.0012]
A: Depth from end of extension case to ball bearing outer ring contact surface
B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface
T: Shim thickness

Specification: 0.05 - 0.25 mm (0.0020 - 0.0098 in)

NOTE: Calculation formula for "T" above is applied when measuring with the ST (398643600 GAUGE).

When not using the ST, When clearances are 0.05 mm (0.0020 in):

T (mm) = (A - α) - ( (B - β) - 0.28) - 0.05
[T (in) = (A - α) - ( (B - β) - 0.011) - 0.0020]
When clearances are 0.25 mm (0.0098 in):
T (mm) = (A - α) - ( (B - β) - 0.28) - 0.25
[T (in) = (A - α) - ( (B - β) - 0.011) - 0.0098] is applied.
T: Shim thickness
A: Depth from end of extension case to ball bearing outer ring contact surface
B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface
α: Thickness of collar used when measuring "A"
β: Thickness of collar used when measuring "B" 0.28 (0.011): Gasket thickness (Unit mm (in) )

5) Select the rear drive shaft shim so that the clearance is within the specified range.

2. SELECTION OF DRIVEN PLATE NO. 3

1) Install the drive plate and driven plate to the center differential carrier.

2) Measure the depth "A" from the mating surface of the extension case to the transfer clutch piston.

3) Using the ST, measure the height "B" from the AT main case mating surface to the end of ST.

ST 398744300 PISTON GUIDE

4) Calculation formula:

When clearances are 0.2 mm (0.008 in):
T (mm) = A - (B - 50) + 0.08
[T (in) = A - (B - 1.97) + 0.0031]
When clearances are 0.6 mm (0.024 in):
T (mm) = A - (B - 50) - 0.32
[T (in) = A - (B - 1.97) - 0.0126]
T: Thickness of driven plate No. 3
A: Depth from mating surface of the extension case to the transfer clutch piston.
B: Height from AT main case mating surface to end of ST
50 mm (1.97 in): Thickness of ST

Specification: 0.2 - 0.6 mm (0.008 - 0.024 in)

NOTE: Calculation formula for "T" above is applied when measuring with the ST (398744300 PISTON GUIDE). When not using the ST, When clearances are 0.2 mm (0.008 in):

T (mm) = A - (B - α - 0.28) - 0.2
[T (in) = A - (B - α - 0.011) - 0.008]
When clearances are 0.6 mm (0.024 in):
T (mm) = A - (B - α - 0.28) - 0.6
[T (in) = A - (B - α - 0.011) - 0.024]
is applied.
T: Thickness of driven plate No. 3
A: Depth from mating surface of the extension case to the transfer clutch piston.
B: Height from the AT main case mating surface to the contact face of the tool that was used as the substitute of the ST.
α: Thickness of tool used when measuring "B"
0.28 (0.011): Gasket thickness (Unit mm (in) )
If it is out of specification, select the driven plate No. 3 to adjust within the specification.

5) Select the driven plate No. 3 so that the clearance is within the specified range.

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