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Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation 2015 Subaru Forester

generation: → 2011 - 2016Release year → 2015 ✔ engine size → 2L ✔      add to compare      read later

MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) > 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 front roller bearing and rear roller bearing of the transfer driven gear.

Grease:

NICHIMOLY N-130 or equivalent

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

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

4. Install the bearing outer race to transfer driven gear.

5. While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.

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

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

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

NOTE:

Measure with bearing outer race and adjusting washer removed.

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

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

t = X ? W + (0.15 — 0.2 mm (0.006 — 0.008 in))

X: Depth of bearing insertion part of the extension case

W: Height between transfer case and taper roller bearing on the transfer driven gear

0.15 — 0.20 mm (0.006 — 0.008 in): Amount of standard protrusion

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

NOTE:

Be sure that it is always within the preload.

Preload of the taper roller bearing (amount of standard protrusion):

0.15 — 0.20 mm (0.006 — 0.008 in)

Adjusting washer (50 ? 61 ? 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 and bearing outer race to the extension case.

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

(A)

Bearing outer race

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

ST    398643600GAUGE

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

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

ST    398643600GAUGE

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

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 gear

30 mm (1.18 in): Thickness of ST 15 mm (0.59 in) ? 2

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 liquid gasket seamlessly to the mating surface of transfer case.

Liquid gasket:

THREE BOND 1215B or equivalent

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

17. Install the extension case assembly to the transfer case.

Tightening torque:

40 N·m (4.1 kgf-m, 29.5 ft-lb)

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

18. Temporarily install the gasket to the transmission case side.

NOTE:

Use a new gasket.

19. Install the extension case assembly along with the transfer case to the transmission case.

(1) While moving the HANDLE to align the spline position, press in the transfer case assembly until the knock pin comes slightly out of transfer case.

ST    18631AA000HANDLE

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

(A)

Transmission case

(B)

Transfer case

(C)

Knock pin

(2) Set and hold the selector lever to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

20. Temporarily tighten the transfer case assembly.

21. Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of straight pin.

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

(A)

Shift lever COMPL

(B)

Remover

22. Operate the selector arm and remover to confirm the correct shifting into each gear is possible.

23. Tighten the transfer case assembly to the specified torque.

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

24. Secure the shift lever COMPL to the shifter arm No. 2 using a straight pin.

NOTE:

Use a new straight pin.

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

(A)

Shift lever COMPL

(B)

Straight pin

25. Install the transfer cover.

(1) Temporarily tighten the transfer cover mounting bolts.

(2) Tighten bolts in order of (B), (A), (C), (D) to the specified torque.

Tightening torque:

15 N·m (1.5 kgf-m, 11.1 ft-lb)

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

26. Apply liquid gasket seamlessly to the mating surface of transmission cover.

Liquid gasket:

THREE BOND 1215B or equivalent

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

27. Install the transmission cover to transfer case.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

2015 Subaru Forester Transmission/Transaxle • Manual Transmission and Differential(6MT) • Transfer CASE and Extension CASE Assembly • Installation

(A)

Transmission cover

28. Install the back-up light switch and the neutral switch.MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) > Switches and Harness > INSTALLATION

29. Install the manual transmission assembly to the vehicle.MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) > Manual Transmission Assembly > INSTALLATION

    2017-02-20 18:51:07    2017-05-11 10:15:25




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