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4WD Transfer Assembly

  1. Install transfer shaft assembly into clutch housing. DO NOT assemble synchronizer sleeve, "O" ring and shim yet. Install bearing case assembly with previously selected shim into clutch housing. Tighten bolts to 19-24 ft. lbs. (26-32 N.m).
  2. Insert dial gauge into backlash adjuster hole so probe rests on driven gear. See Fig 1. Pull on transfer shaft assembly until backlash becomes zero. Measure clearance between clutch housing end face and ball bearing flange. See Fig 2.
    Fig 1: Measuring Bevel Gear Backlash
    G93F25515Courtesy of SUBARU OF AMERICA, INC.
    Fig 2: Measuring Ball Bearing Flange Clearance
    G93G25516Courtesy of SUBARU OF AMERICA, INC.
  3. Select transfer shaft assembly shim with thickness equal to measured clearance minus about .008" (.20 mm). See TRANSFER SHAFT ASSEMBLY SHIM table. Remove bearing case assembly and transfer shaft assembly. Install selected shim. Reinstall bearing case and transfer shaft assemblies. Install transfer shaft assembly to clutch housing using 2 bolts.
    TRANSFER SHAFT ASSEMBLY SHIM

    Part No. Thickness In. (mm)
    841968601 .0059 (.150)
    841968602 .0079 (.200)
    841968603 .0098 (.250)
    841968604 .0118 (.300)
    841968605 .0197 (.500)
    841968606 .0069 (.175)
    841968607 .0089 (.225)
    841968608 .0108 (.275)
  4. Hold transfer shaft assembly in position. Measure backlash by moving hypoid driven gear. If backlash is not .0039-.0059" (.100-.150 mm), select another transfer shaft assembly shim. Remove bearing case and transfer shaft assemblies.
  5. Install transfer shaft assembly with selected shim and "O" ring. Tighten bolts to 13-16 ft. lbs. (18-22 N.m). Apply thin coat of Red lead to hypoid driven gear teeth surfaces. Install bearing case assembly and bevel gear height shim onto main case. Tighten bolts to 19-24 ft. lbs. (26-32 N.m). Check for backlash of .0039-.0059" (.100-.150 mm).
  6. Hold hypoid driven gear splines in position and rotate transfer shaft several complete turns. Inspect tooth contact pattern. See Fig 3. Readjust for proper backlash and contact pattern.
  7. Press oil seal into extension case. Install extension housing and gasket onto clutch housing. Tighten bolts to 17-19 ft. lbs. (23-26 N.m).
  8. Press oil seal into transfer side case. Press locating dowel into transfer side case. Install transfer shifter shaft into side cover. Install shifter shaft end clip. Locating dowel height should be .39-.43" (10.0-11.0 mm). Transfer shifter shaft height should be .376-.392" (9.55-9.95 mm).
  9. Install seal over locating dowel. Install transfer side cover, adjusting shim, transfer shaft assembly bearing and gasket. Tighten bolts to 13-16 ft. lbs. (18-22 N.m).
  10. Install transfer shifter fork onto transfer shifter rail, drive in pin and install with synchronizer sleeve into side cover from main case side. Install diaphragm from side cover side. Install transfer shifter lever and washer to transfer shifter shaft. Install clip.
  11. Install diaphragm cover. Tighten bolts to 81-94 INCH lbs. (9.1-10.6 N.m). Install transfer cover and gasket. Tighten bolts to 81-94 INCH lbs. (9.1-10.6 N.m).
  12. Install backlash measurement hole plug and gasket. Tighten to 30-35 ft. lbs. (41-47 N.m). Install ball, spring and plug into clutch housing. Tighten plug to 13-15 ft. lbs. (18-21 N.m).
Fig 3: Identifying Gear Tooth Contact Patterns
G93H25517Courtesy of SUBARU OF AMERICA, INC.
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