Extension Case: Assembly

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

MPT MODEL
1. Using the ST and a press, press in a new oil seal.
  1. ST 498057300 INSTALLER
2. Press in the dust cover.
3. Install the transfer clutch pipe to extension case without bending pipe.
  
  Fig 1: Installing Transfer Clutch Pipe To Extension Case Without Bending Pipe
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the transfer clutch assembly to the case.
  NOTE:
  - Be careful not to damage the seal rings.
  - Insert the clutch assembly fully into position until the bearing shoulder bottoms.
  Fig 2: Installing Transfer Clutch Assembly To Case
  Courtesy of SUBARU OF AMERICA, INC.
VTD MODEL
1. Press new oil seal using ST and a press.
  1. ST 498057300 INSTALLER
2. Press dust cover.
3. Install the transfer clutch pipe onto the extension case, taking care not to bend the pipe.
  
  Fig 3: Installing Transfer Clutch Pipe Onto Extension Case
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the test plug.
  1. Tightening torque: 13 N.m (1.3 kgf.m, 9.4 ft.lb)
  Fig 4: Installing Test Plug
  Courtesy of SUBARU OF AMERICA, INC.
5. Insert the multi-plate clutch, drive plates, driven plates, and spring retainer.
  
  Fig 5: Inserting Multi-Plate Clutch, Drive Plates, Driven Plates & Spring Retainer
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the snap ring using special tools 1, 2, and 3.
  
  Fig 6: Installing Snap Ring Using Special Tools
  Courtesy of SUBARU OF AMERICA, INC.