Subaru Outback (BR): Transfer Case and Extension Case Assembly

A: REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the back-up light switch and the neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

3) Remove the transfer case together with the extension case assembly.

1. Remove the transmission cover.

1. Transmission cover

2. Set and hold the selector lever COMPL to the 1st-2nd side, and remove the transfer case and extension case assembly as a unit.

4) Use the ST to push out the spring pin and remove the shift lever COMPL from shifter arm No. 2.

ST 398791700 SPRING PIN REMOVER 2

1. Shift lever COMPL
2. Spring pin

5) Remove the extension case assembly.

B: INSTALLATION

1) Install the center differential and transfer driven gear into the transfer case.

2) Remove the bearing outer race and thrust washer from the extension case.

1. Bearing outer race
2. Extension case

3) Install the bearing outer race to transfer driven gear.

4) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.

5) Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.

6) Measure depth "X" of bearing insertion part of the extension case.

NOTE: Measure with bearing outer race and thrust washer removed.

7) Calculate the thrust washer thickness "t" using the following calculation.

t = X - W + (0.15 - 0.20 mm (0.006 - 0.008 in) )

8) Select the washer with the nearest value in the following table.

NOTE: Be sure that it is always within the preload.

Preload of the taper roller bearing (amount of standard protrusion): 0.15 - 0.20 mm (0.006 - 0.008 in)

9) Install the thrust washer to extension case.

10) Replace the bearing outer race attached to the transfer driven gear with the extension case.

11) Measure the depth "S" between transfer case and center differential.

ST 398643600 GAUGE

12) Measure the height "T" between the extension case and transfer drive gear.

ST 398643600 GAUGE

13) Calculate the thrust washer thickness "U" using the following calculation.

U = S + T - 30 mm (1.18 in) [Thickness of ST]

NOTE: Thickness of ST: 15 mm (0.59 in)

14) Select a suitable washer in the following table.

Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 in)

15) Install the selected thrust washer to center differential.

16) Apply a proper amount of liquid gasket to the transfer case mating surface.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

17) Install the extension case assembly to the transfer case.

Tightening torque: 40 N*m (4.1 kgf-m, 29.5 ft-lb)

18) Install the gasket, and install the transfer case along with the extension case assembly to the transmission case.

NOTE: Use a new gasket.

1. Insert the axle shaft and hold, then move the ST (HANDLE) to align the spline position to install.

ST 18631AA000 HANDLE
Part No. 38415AA100 Axle shaft

NOTE: Push the transfer case assembly until the knock pin protrudes slightly from the transfer case.

1. Transmission case
2. Transfer case
3. Knock pin

2. Set and hold the selector lever to the 1st- 2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.

19) Temporarily tighten the transfer case assembly.

20) Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.

1. Shift lever COMPL
2. Remover

21) Operate the selector lever and shift lever COMPL to confirm the correct shifting into each gear is possible.

22) Tighten the transfer case assembly to the specified torque.

Tightening torque: 24.5 N*m (2.5 kgf-m, 18.1 ft-lb)

23) Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.

NOTE: Use new spring pin.

1. Shift lever COMPL
2. Spring pin

24) Install the transmission cover. <Ref. to 6MT-53, INSTALLATION, Shift Link Assembly.>

C: DISASSEMBLY

1. TRANSFER CASE

1) Remove the interlock plate.

NOTE: Do not remove the interlock plate mounting bolt if the parts are assembled as a transmission assembly.

Do not attempt to replace the interlock plate unless necessary. Do not reuse the bolts and gaskets once they are removed.

1. Interlock plate

2) Remove the shift link assembly. <Ref. to 6MT- 50, REMOVAL, Shift Link Assembly.>

2. EXTENSION CASE

1) Remove the transfer drive gear assembly. <Ref. to 6MT-45, REMOVAL, Transfer Drive Gear.>

2) Remove the oil seal from the extension case.

<Ref. to 6MT-35, Oil Seal.>

D: ASSEMBLY

1. TRANSFER CASE

1) Install the shift link assembly to the transfer case. <Ref. to 6MT-53, INSTALLATION, Shift Link Assembly.>

2) Install the interlock plate to the transfer case.

NOTE:

• Use a new bolt and gasket.
• Before installing the interlock plate, clean the screw threads.

Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb)

1. Interlock plate

2. EXTENSION CASE

1) Using the ST, install the oil seal to the extension case. <Ref. to 6MT-35, Oil Seal.>

NOTE: Use a new oil seal.

2) Install the transfer drive gear to the extension case. <Ref. to 6MT-45, INSTALLATION, Transfer Drive Gear.>

Transfer Drive Gear

A: REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the back-up light switch neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

3) Remove the transfer case together with the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

4) Remove the extension case assembly.

5) Remove the transfer driven gear. <Ref. to 6MT- 47, REMOVAL, Transfer Driven Gear.>

6) Remove the transfer drive gear.

B: INSTALLATION

1) Install the transfer drive gear.

Tightening torque: 26 N*m (2.7 kgf-m, 19.2 ft-lb)

2) Install the transfer driven gear. <Ref. to 6MT-47, INSTALLATION, Transfer Driven Gear.>

3) Install the extension case assembly.

4) Install the transfer case and the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

5) Install the back-up light switch neutral position switch. <Ref. to 6MT-37, INSTALLATION, Switches and Harness.>

6) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-29, INSTALLATION, Manual Transmission Assembly.>

C: DISASSEMBLY

1) Remove the snap ring.

2) Remove the ball bearing.

ST 899864110 REMOVER

3) Remove the snap ring from transfer drive gear, and remove the needle bearing.

D: ASSEMBLY

1) Install the needle bearing and snap ring to the transfer drive gear.

2) Set the ST to the bearing inner race, then install the transfer drive shaft.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 398177700 INSTALLER

3) Install the snap ring on the transfer drive shaft.

4) Inspect the clearance between the snap ring and the ball bearing. <Ref. to 6MT-46, INSPECTION, Transfer Drive Gear.>

E: INSPECTION

1) Bearing

Replace the bearings in the following cases.

• In case of broken or rusty bearings
• In case of wear or damage
• When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.

2) Drive gear

If the drive gear tooth surface and shaft are excessively broken or damaged, replace the drive gear.

3) Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge.

Clearance: 0.01 - 0.15 mm (0.0004 - 0.0059 in)

If the measurement is not within specification, select a suitable snap ring and replace it.

Transfer Driven Gear

A: REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the back-up light switch neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

3) Remove the transfer case together with the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

4) Remove the extension case assembly.

5) Remove the transfer driven gear.

6) Remove bearing outer races from the extension case and transfer case.

1. Bearing outer race (Transfer case side)
2. Bearing outer race (Extension case side)

B: INSTALLATION

1) Select a thrust washer. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

2) Install the bearing outer races to extension case and transfer case.

1. Bearing outer race
2. Bearing outer race
3. Transfer case
4. Extension case

3) Install the transfer driven gear.

4) Install the transfer case and the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

5) Install the back-up light switch and the neutral position switch. <Ref. to 6MT-37, INSTALLATION, Switches and Harness.>

6) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-29, INSTALLATION, Manual Transmission Assembly.>

C: DISASSEMBLY

1) Using the ST, remove the roller bearing (extension case side).

ST 498077000 REMOVER

1. Roller bearing

2) Using ST1 and ST2, remove the roller bearing (transfer case side).

ST1 498077000 REMOVER
ST2 899864100 REMOVER

1. Roller bearing

D: ASSEMBLY

1) Using the ST, install the roller bearing (extension case side).

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 398177700 INSTALLER
ST2 899864100 REMOVER

1. Roller bearing

2) Using ST, install the roller bearing (transfer case side).

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499757002 INSTALLER

1. Roller bearing

E: INSPECTION

1) Bearing

Replace the bearings in the following cases.

• In case of broken or rusty bearings
• In case of wear or damage
• When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.

2) Driven gear

If the tooth face of driven gear and the shaft are excessively broken or damaged, replace the driven gear.

Center Differential

A: REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the back-up light switch neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

3) Remove the transfer case together with the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

4) Remove the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

5) Remove the transfer driven gear. <Ref. to 6MT- 47, REMOVAL, Transfer Driven Gear.>

6) Remove the center differential.

B: INSTALLATION

1) Install the center differential into transfer case.

2) Install the transfer driven gear. <Ref. to 6MT-47, INSTALLATION, Transfer Driven Gear.>

3) Install the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

4) Install the transfer case together with the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

5) Install the back-up light switch neutral position switch. <Ref. to 6MT-37, INSTALLATION, Switches and Harness.>

6) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-29, INSTALLATION, Manual Transmission Assembly.>

C: DISASSEMBLY

Remove the ball bearing using ST.

NOTE:

• Center differential is a non-disassembled part which should not be disassembled.
• Do not reuse the ball bearing.

ST 498077600 CENTER DIFFERENTIAL BEARING REMOVER

D: ASSEMBLY

Install the ball bearing to the center differential assembly.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Use a new ball bearing.

1. Ball bearing

E: INSPECTION

1) Bearing

Replace the bearings in the following cases.

• In case of broken or rusty bearings
• In case of wear or damage
• When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
• When bearing has other defects.

2) Center differential

If there is wear or damage, replace the center differential case assembly.

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