Content .. 618 619 620 621 ..

Subaru Legacy III (2000-2003 year). Manual - part 620

MT-48

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER CASE AND EXTENSION CASE ASSEMBLY

7) Select nearest washer in the following table:

Standard clearance between thrust washer and
taper roller bearing:

0.2 — 0.3 mm (0.008 — 0.012 in)

NOTE:
Ensure clearance is within the specified value.

8) Fit thrust washers on transfer drive shaft.
9) Install bearing cone into extension case.
10) Measure depth “S” between transfer case and
center differential.
ST

398643600

GAUGE

11) Measure depth “T” between extension case
and transfer drive gear.
ST

398643600

GAUGE

12) Calculate space “U” using the following equa-
tion: U = S + T

−

30 mm (1.18 in) [Thickness of ST]

13) Select suitable washer in the following table:

Standard clearance:

0.15 — 0.35 mm (0.0059 — 0.0138 in)

14) Fit thrust washer on center differential.
15) Apply proper amount of liquid gasket to the
transfer case mating surface.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007)

Thrust washer (50

Part No.

Thickness mm (in)

803050060

0.50 (0.0197)

803050061

0.55 (0.0217)

803050062

0.60 (0.0236)

803050063

0.65 (0.0256)

803050064

0.70 (0.0276)

803050065

0.75 (0.0295)

803050066

0.80 (0.0315)

803050067

0.85 (0.0335)

803050068

0.90 (0.0354)

803050069

0.95 (0.0374)

803050070

1.00 (0.0394)

803050071

1.05 (0.0413)

803050072

1.10 (0.0433)

803050073

1.15 (0.0453)

803050074

1.20 (0.0472)

803050075

1.25 (0.0492)

803050076

1.30 (0.0512)

803050077

1.35 (0.0531)

803050078

1.40 (0.0551)

803050079

1.45 (0.0571)

MT-00122

Thrust washer

Part No.

Thickness mm (in)

803036050

0.9 (0.035)

803036054

1.0 (0.039)

803036051

1.1 (0.043)

803036055

1.2 (0.047)

803036052

1.3 (0.051)

803036056

1.4 (0.055)

803036053

1.5 (0.059)

803036057

1.6 (0.063)

803036058

1.7 (0.067)

MT-00123

MT-00124

MT-49

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER CASE AND EXTENSION CASE ASSEMBLY

16) Install extension assembly into transfer case.

Tightening torque:

40 N·m (4.1 kgf-m, 29.7 ft-lb)

17) Install shifter arm to transfer case.

18) Hang the shifter arm on the 3rd-4th fork rod.

19) Install transfer case with extension case as-
sembly to transmission case.

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

C: DISASSEMBLY

1. TRANSFER CASE

1) Remove reverse check assembly. <Ref. to MT-
56, REMOVAL, Reverse Check Sleeve.>
2) Remove oil guide.

2. EXTENSION CASE

1) Remove transfer drive gear assembly. <Ref. to
MT-51, REMOVAL, Transfer Drive Gear.>
2) Remove shift bracket.

3) Remove oil seal from extension case. <Ref. to
MT-41, Oil Seal.>

(A) Shifter arm

(B) 3rd - 4th fork rod

MT-00125

MT-00126

MT-00127

( A )

( B )

MT-00116

MT-00129

MT-00130

MT-50

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER CASE AND EXTENSION CASE ASSEMBLY

D: ASSEMBLY

1. EXTENSION CASE

1) Using ST, install oil seal to extension case. <Ref.
to MT-41, Oil Seal.>

NOTE:
Use new oil seal.
2) Install shift bracket to extension case.

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

3) Install transfer drive gear to extension case.
<Ref. to MT-51, INSTALLATION, Transfer Drive
Gear.>

2. TRANSFER CASE

1) Install oil guide to transfer case.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

2) Install reverse check sleeve assembly to transfer
case. <Ref. to MT-56, INSTALLATION, Reverse
Check Sleeve.>

MT-00130

MT-00129

MT-51

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER DRIVE GEAR

10.Transfer Drive Gear

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove back-up light switch and neutral posi-
tion switch. <Ref. to MT-42, REMOVAL, Switches
and Harness.>
3) Remove transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove extension case assembly.
5) Remove transfer driven gear.
6) Remove transfer drive gear.

B: INSTALLATION

1) Install transfer drive gear.

Tightening torque:

26 N·m (2.7 kgf-m, 20 ft-lb)

2) Install transfer driven gear.
3) Install the extension case assembly.
4) Install transfer case and extension case assem-
bly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
5) Install back-up light switch and neutral position
switch. <Ref. to MT-43, INSTALLATION, Switches
and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Remove snap ring.

2) Remove ball bearing.

D: ASSEMBLY

1) Set ST to inner race of bearing and install to
drive shaft.
ST

39817700

INSTALLER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)

2) Install snap ring on transfer drive shaft.
3) Inspect clearance between snap ring and inner
race of ball bearing. <Ref. to MT-52, INSPECTION,
Transfer Drive Gear.>

MT-00133

MT-00135

MT-00136

MT-00137

Content .. 618 619 620 621 ..