2021 Subaru Outback BaseFACTORY OEM SERVICE PROCEDURE

Transfer Clutch: Assembly

  1. Install the transfer clutch piston, return spring and transfer clutch piston seal.
    NOTE:
    • Apply CVTF to the seal section of transfer clutch piston.
    • Apply CVTF to the lip section of transfer clutch piston seal.
    G13950617Courtesy of SUBARU OF AMERICA, INC.
  2. Compress the return spring using the ST and a press to install the snap ring.

    Preparation tool: 

    ST: COMPRESSOR SPECIAL TOOL (18762AA001)

    G13950618Courtesy of SUBARU OF AMERICA, INC.
  3. Blow compressed air through the hole shown in the figure, and check the transfer clutch piston operation.
    G13950619Courtesy of SUBARU OF AMERICA, INC.
  4. Select the transfer clutch plate set and pressure plate (rear side).
    NOTE: The pressure plate (front side) is included in the transfer clutch plate set.
    1. Set the pressure plate (rear side) and transfer clutch plate set to the rear drive shaft, and then install the snap ring.
      NOTE: Face the smooth side of the pressure plate (rear side) toward the transfer clutch plate set.
      G13950620Courtesy of SUBARU OF AMERICA, INC.
    2. Set the shim, etc. (A) between the snap ring and pressure plate (front side) so that each plate does not tilt.
      G13950621Courtesy of SUBARU OF AMERICA, INC.
    3. Measure the clearance "C" between the snap ring and pressure plate (front side) using a thickness gauge.

      Service limit: 

      1.45 mm (0.057 in)

      G13950622Courtesy of SUBARU OF AMERICA, INC.
    4. If the value exceeds the limit, perform the following procedures.
      1. Measure the thickness of the pressure plate (front side) and pressure plate (rear side).
      2. Replace with a new transfer clutch plate set that includes a pressure plate (front side) whose thickness is close to the measured thickness of pressure plate (front side), and perform measurement from step (2) again.

        Initial standard: 

        0.7 - 1.1 mm (0.03 - 0.04 in)

      3. If it exceeds the initial standard value, adjust the thickness of pressure plate (rear side) so that the value falls within the initial standard.
  5. Press-fit a new ball bearing using ST1, ST2 and a press.
    NOTE: Apply CVTF to the press-fitting area.

    Preparation tool: 

    ST1: INSTALLER (398177700)

    ST2: EXTENSION DRIVE SHAFT (927130000)

    G13950623Courtesy of SUBARU OF AMERICA, INC.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.