Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 2004 3 - Transmission Manual and Differential Transfer Case and Extension Case Assembly

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Transfer Case and Extension Case Assembly


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                 TRANSFER CASE AND EXTENSION CASE ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

10.Transfer Case and Extension                           2) Remove the bearing outer race from extension
                                                         case.
   Case Assembly
                                                                            (B)
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. 
2) Remove the back-up light switch and neutral po-
sition switch. 
3) Remove the transfer case with extension case
assembly.                                                                                        MT-00119

                                                                (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.


                                         MT-00116

4) Remove the shifter arm.
5) Remove the extension case assembly.


                                                                                                   W



                                                                                                 MT-00120

                                                         5) Measure the depth "X".
                                                         NOTE:
                                                         Measure with bearing cone and thrust washer re-
                                                         moved.
                                         MT-00117

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



                                                                 X



                                                                                                 MT-00121

                                                         6) Calculate the space "t" using the following equa-
                                                         tion: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
                                                         7) Select the nearest washer in the following table:
                                         MT-00118
                                                         Standard clearance between thrust washer and
                                                         taper roller bearing:
                                                           0.2 -- 0.3 mm (0.008 -- 0.012 in)
                                                         NOTE:
                                                         Set the clearance within standard clearance.


                                                    5MT-42
                  TRANSFER CASE AND EXTENSION CASE ASSEMBLY
                                                              MANUAL TRANSMISSION AND DIFFERENTIAL

                                                         12) Calculate the space "U" using the following
              Thrust washer (50 



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