Subaru Crosstrek manuals

Subaru Crosstrek Service Manual: Installation

MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Transfer Case and Extension Case Assembly

INSTALLATION

1. Clean the mating surfaces of the transmission case, transfer case and extension case.

2. Apply a coat of grease to the taper roller bearing (transfer case side) of transfer driven gear and the roller rolling surface of the taper roller bearing (extension case side).

Grease:

NICHIMOLY N-130 or equivalent

3. Install the center differential and the transfer driven gear.

4. Install the taper roller bearing (extension case side) outer race to the transfer driven gear.

5. While pressing the taper roller bearing (extension case side) outer race horizontally, rotate the transfer driven gear for ten turns.

6. Measure the height “W” between transfer case and taper roller bearing (transfer case side) on the transfer driven gear.

7. Measure the depth “X” of taper roller bearing insertion part of the extension case.

NOTE:

Measure while the taper roller bearing (extension case side) outer race, dish plate and adjusting washer are removed.

8. Calculate the adjusting washer thickness “t” using the following calculation.

t = X − W − (1.715 — 1.765 mm (0.686 — 0.706 in))

X: Depth of taper roller bearing insertion part of extension case

W: Height between transfer case and taper roller bearing (transfer case side) on transfer driven gear

9. Select the adjusting washer with the nearest value in the following table.

Adjusting washer (61 ? 50 ? t)

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)

10. Install the selected adjusting washer, dish plate and taper roller bearing (extension case side) outer race.

NOTE:

Make sure the dish plate is installed in the proper direction.

(A)

Taper roller bearing (extension case side) outer race

(B)

Dish plate

(C)

Adjusting washer

(D)

Extension case

(1)

Paint side

11. Measure the depth “S” between the transfer case + ST and the center differential.

ST 398643600GAUGE

12. Measure the height “T” between the extension case + ST and the transfer drive gear.

ST 398643600GAUGE

13. Calculate the adjusting washer thickness “U” using the following calculation.

U = S + T − 30 mm (1.18 in) − (0.15 — 0.35 mm (0.0059 — 0.0138 in))

S: Depth between the transfer case + ST and the center differential

T: Height between the extension case + ST and the transfer drive gear

30 mm (1.18 in): Thickness of ST (? 2 pieces)

0.15 — 0.35 mm (0.0059 — 0.0138 in): Clearance

14. Select a suitable adjusting washer in the following table.

Clearance:

0.15 — 0.35 mm (0.0059 — 0.0138 in)

Adjusting 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)

803036080

1.8 (0.071)

803036081

1.9 (0.075)

15. Install the adjusting washer to center differential.

16. Apply an appropriate amount of liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

17. Install the extension case assembly.

Tightening torque:

40 N·m (4.1 kgf-m, 29.5 ft-lb)

18. Install the shifter arm.

NOTE:

Apply transmission gear oil to the oil seal lips.

19. Attach the gasket.

NOTE:

Use a new gasket.

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

(A)

Shifter arm

(B)

3rd-4th fork rod

21. Install the transfer case together with the extension case assembly.

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

22. Install the back-up light switch and the neutral position switch. Switches and Harness > INSTALLATION">

23. Install the manual transmission assembly to the vehicle. Manual Transmission Assembly > INSTALLATION">

Disassembly
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Transfer Case and Extension Case AssemblyDISASSEMBLY1. TRANSFER CASE1. Remove the reverse check sleeve assembly. Reverse Check Sleeve > REMOVAL" ...

Transfer drive gear
...

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Caution
FRONT SUSPENSION > General DescriptionCAUTION• Wear appropriate work clothing, including a helmet, protective goggles and protective shoes when performing any work.• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, d ...

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