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Shift Link Assembly: Installation

  1. Install the plunger and check ball spring to transmission cover.
    NOTE: Use a new seal ring.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    Fig 1: Exploded View Of Plunger
    G07915130Courtesy of SUBARU OF AMERICA, INC.
  2. Using the ST, install the needle bearing to the transfer case.
    NOTE:
    • Use a new needle bearing.
    • If the press-fit depth exceeds the service limit, replace with a new needle bearing.

    ST1 18763AA000 COMPRESSOR SHAFT

    ST2 498277200 STOPPER SET

    Press-fit depth of needle bearing: 

    A: 8.5±0.2 mm (0.33±0.01 in) from the end of transfer case 

    Fig 2: Identifying Press-Fit Depth Of Needle Bearing
    G07915131Courtesy of SUBARU OF AMERICA, INC.

    B: 0.2±0.2 mm (0.01±0.01 in) from the end of transfer case 

    Fig 3: Identifying Press-Fit Depth Of Needle Bearing
    G07915132Courtesy of SUBARU OF AMERICA, INC.
  3. 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

    Fig 4: Identifying Cylinder Head Tables ST1 498267300 And ST2 498267200
    G07915126Courtesy of SUBARU OF AMERICA, INC.
  4. Using the ST, install the roller bearing to the transfer case.
    NOTE:
    • Use a new bearing.
    • Gradually perform the press-fit operation while measuring the press-fit depth.
    • If the press-fit depth exceeds the service limit, replace with a new bearing.

    ST 899864100 REMOVER

    Press-fit depth of roller bearing: 

    A: 5.1±0.2 mm (0.20±0.01 in) from the finished surface of transfer case 

    Fig 5: Identifying Press-Fit Depth Of Roller Bearing
    G07915134Courtesy of SUBARU OF AMERICA, INC.
  5. Flip over the transfer case, and set an iron plate between transfer case and ST.
    NOTE:
    • Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
    • Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.
  6. Using the ST, install the roller bearing to the transfer case.
    NOTE:
    • Use a new bearing.
    • Gradually perform the press-fit operation while measuring the press-fit depth.
    • If the press-fit depth exceeds the service limit, replace with a new bearing.

    ST 899864100 REMOVER

    Press-fit depth of roller bearing: 

    A: 0±0.2 mm (0±0.01 in) from the end of transfer case 

    Fig 6: Identifying Press-Fit Depth Of Roller Bearing
    G07915135Courtesy of SUBARU OF AMERICA, INC.
  7. Using the ST, install the oil seal to the transfer case.
    NOTE:
    • Use a new oil seal.
    • The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
    • Apply transmission gear oil to the oil seal lips.

    ST 18657AA000 INSTALLER

    Press-fit depth of oil seal: 

    1±0.2 mm (0.04±0.01 in) from the end of transfer case 

    Fig 7: Installing Oil Seal To Transfer Case Using ST
    G06652357Courtesy of SUBARU OF AMERICA, INC.
  8. Insert the shifter arm into the selector arm, and fix with a spring pin.
    NOTE: Use new spring pin.

    ST 398791700 SPRING PIN REMOVER 2

    Fig 8: Inserting Shifter Arm Into Selector Arm
    G07915137Courtesy of SUBARU OF AMERICA, INC.
  9. Install the shifter arm No. 2, washers and thrust bearing to transfer case.
    Fig 9: Installing Shifter Arm No. 2, Washers And Thrust Bearing To Transfer Case
    G07915138Courtesy of SUBARU OF AMERICA, INC.
  10. Install the shifter arm collar and neutral set spring to transfer case.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 10: Installing Shifter Arm Collar And Neutral Set Spring To Transfer Case
    G06652360Courtesy of SUBARU OF AMERICA, INC.
  11. Install the selector arm No. 2 to neutral set spring.
    Fig 11: Identifying Selector Arm No. 2 And Neutral Set Spring
    G07915140Courtesy of SUBARU OF AMERICA, INC.
  12. Insert the selector lever COMPL into the selector arm No. 2, and fix with a spring pin.
    NOTE: Use new spring pin.

    ST 398791700 SPRING PIN REMOVER 2

    Fig 12: Inserting Selector Lever Compl Into Selector Arm No. 2
    G07915141Courtesy of SUBARU OF AMERICA, INC.
  13. Insert a new straight pin.
    Fig 13: Identifying Straight Pin And Selector Lever Compl
    G07915142Courtesy of SUBARU OF AMERICA, INC.
  14. Apply liquid gasket seamlessly to the mating surface of transmission cover.

    Liquid gasket: 

    THREE BOND 1215 (Part No. 004403007) or equivalent 

    Fig 14: Identifying Liquid Gasket
    G06652364Courtesy of SUBARU OF AMERICA, INC.
  15. Install the transmission cover to transfer case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    Fig 15: Identifying Transmission Cover
    G07915144Courtesy of SUBARU OF AMERICA, INC.
  16. Attach the extension assembly to the transfer case. Refer to Transfer Case and Extension Case Assembly  .
  17. Install the transfer case and the extension case assembly. Refer to Transfer Case and Extension Case Assembly  .
  18. Install the back-up light switch and the neutral position switch. Refer to Switches and Harness  .
  19. Install the manual transmission assembly to the vehicle. Refer to Manual Transmission Assembly  .
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