Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 404

5MT-37

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

15) Install the adjusting washer to center differen-

tial.

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) Attach the extension assembly to the transfer

case.
Tightening torque:

40 N·m (4.1 kgf-m, 29.5 ft-lb)

18) Attach the shifter arm to transfer case.

19) Attach the gasket.
NOTE:

Use a new gasket.

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

21) Install the extension case assembly along with

the transfer case to the transmission case.
Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

MT-00124

MT-00117

MT-00126

(A) Shifter arm
(B) 3rd-4th fork rod

MT-00127

(A)

(B)

MT-02614

5MT-38

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

1. TRANSFER CASE

1) Remove the reverse check sleeve assembly.

<Ref. to 5MT-46, REMOVAL, Reverse Check

Sleeve.>

2) Remove the oil guide.

3) Remove the oil seal.

4) Set ST1, ST2 and transfer case to a press.
NOTE:

• Set the ST2 under ST1.

• Set the transfer case so that the hole for shifter

arm is positioned vertically.

ST1 498267300

CYLINDER HEAD TABLE

ST2 498267200

CYLINDER HEAD TABLE

5) Using the round bar with diameter of 22 mm

(0.87 in) or 23 mm (0.91 in), remove the roller bear-

ing.

2. EXTENSION CASE

1) Remove the transfer drive gear assembly. <Ref.

to 5MT-41, REMOVAL, Transfer Drive Gear.>

2) Remove the shift bracket.

3) Remove the oil seal from the extension case.

<Ref. to 5MT-31, Oil Seal.>

MT-01563

MT-02138

ST1

ST2

ST2

ST1

MT-02139

MT-00130

5MT-39

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY

1. EXTENSION CASE

1) Using the ST, install the oil seal to the extension

case. <Ref. to 5MT-31, Oil Seal.>
NOTE:

Use a new oil seal.

2) Install the shift bracket to extension case.
Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

3) Install the transfer drive gear to the extension

case. <Ref. to 5MT-41, INSTALLATION, Transfer

Drive Gear.>

2. TRANSFER CASE

1) Set the ST1, ST2, iron plate and the transfer

case to the press.
NOTE:

• Set the ST2 under ST1.

• Set the transfer case so that the hole for shifter

arm is positioned vertically.

• Insert the iron plate which is thicker than the ex-

posed length of the transfer case knock pin be-

tween the ST and transfer case.

• Set the iron plate so that the transfer case knock

pin does not ride on the iron plate.

ST1 498267300

CYLINDER HEAD TABLE

ST2 498267200

CYLINDER HEAD TABLE

2) Press-fit the roller bearing using the ST.
Press-fit depth of needle bearing:

A: 0

±

0.2 mm (0

±

0.01 in) from the end of trans-

fer case

ST 899864100

REMOVER

MT-00130

(A) Iron plate

MT-02141

(A)

ST2

ST2

ST1

ST1

MT-02142

ST

A

5MT-40

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

3) Remove the iron plate, and turn over the transfer

case.
NOTE:

Set the transfer case so that the hole for shifter arm

is positioned vertically.

4) Press-fit the roller bearing using the ST.
Press-fit depth of needle bearing:

A: 0

±

0.2 mm (0

±

0.01 in) from the end of trans-

fer case

ST 899864100

REMOVER

5) Install the shifter arm to the transfer case, and

make sure that the shift arm moves smoothly.

6) Install the oil guide to the transfer case.
NOTE:

Use a new installing bolt.
Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

7) Install the reverse check sleeve assembly to the

transfer case. <Ref. to 5MT-46, INSTALLATION,

Reverse Check Sleeve.>

8) Install the oil seal.
Press-fit depth of oil seal:

A: 1

±

0.2 mm (0.04

±

0.01 in) from the end of

transfer case

MT-02140

ST

A

MT-01563

MT-02299

A