SUBARU FORESTER 2004 Service Repair Manual

4AT(H4DOTC 2.5)-2
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
General Description
1. General Description
A: SPECIFICATION
Trouble shooting for 2.5 L turbo model is included
in “4AT(H4DOTC)” section.
<Ref. to 4AT(H4DOTC)-2, Basic Diagnostic Proce-
dure.>

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

MANUAL TRANSMISSION AND
DIFFERENTIAL
5MT
Page
1. General Description ....................................................................................2
2. Transmission Gear Oil ..............................................................................31
3. Manual Transmission Assembly ...............................................................32
4. Transmission Mounting System ................................................................39
5. Oil Seal......................................................................................................41
6. Differential Side Retainer Oil Seal.............................................................42
7. Switches and Harness ..............................................................................43
8. Vehicle Speed Sensor...............................................................................46
9. Preparation for Overhaul ...........................................................................47
10. Oil Pump ...................................................................................................48
11. Transfer Case and Extension Case Assembly..........................................50
12. Transfer Drive Gear ..................................................................................54
13. Transfer Driven Gear ................................................................................56
14. Center Differential .....................................................................................58
15. Reverse Check Sleeve..............................................................................59
16. Transmission Case ...................................................................................62
17. Main Shaft Assembly For Single-Range ...................................................69
18. Main Shaft Assembly For Dual-Range ......................................................77
19. Input Shaft Assembly ................................................................................83
20. Drive Pinion Shaft Assembly .....................................................................87
21. Front Differential Assembly .......................................................................96
22. Speedometer Gear..................................................................................103
23. Reverse Idler Gear ..................................................................................104
24. Shifter Fork and Rod ...............................................................................106
25. Counter Gear ..........................................................................................109
26. General Diagnostic..................................................................................111

5MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil
Model2.0 L Non-
turbo2.5 L Non-
turbo2.0 L Turbo
2.5 L Turbo
Except
EuropeEurope
Ty p e5×2-forward speeds with syn-
chromesh and 2-reverse5-forward speeds with synchromesh and 1-
reverse
Transmission gear ratio1st 3.454
2nd 2.062 1.947
3rd 1.448 1.366
4th 1.088 0.972
5th 0.825 0.780 0.738
Reverse 3.333
Auxiliary transmission gear ratioHigh 1.000 —
Low 1.447 1.196 —
Front reduction gear FinalType of gear Hypoid
Gear ratio 4.111 4.444
Rear reduction gearTransferType of gear Helical
Gear ratio 1.000 1.000 1.081 1.000
FinalType of gear Hypoid
Gear ratio 4.111 4.444 4.111 4.444
Front differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 4.02 (4.2 US qt, 3.5 Imp qt)3.52 (3.7 US
qt, 3.1 Imp
qt)3.92 (4.1 US
qt, 3.4 Imp
qt)3.52 (3.7 US
qt, 3.1 Imp
qt)
(1) Item
(2) Transmission gear oil
(3) API classification
(4) SAE viscosity No. and applicable temperature
MT-00001
(1)
(4) GL-5(3) (2)
( C)( F)-30 -26 -15 15
90
85W
80W
75W -9025 30 -5 0-22-1523328659775

5MT-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of main shaft rear plate
Snap ring to counter washer clearance :
0.05 — 0.35 mm (0.0020 — 0.0138 in)
Input shaft holder adjustment
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque :
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6
ft-lb)
5. INPUT SHAFT ASSEMBLY
Snap ring (Outer-28) to ball bearing clear-
ance :
0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Inner-68) to bearing clearance :
0 — 0.12 mm (0 — 0.0047 in)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub
clearance :
0.060 — 0.100 mm (0.0024 — 0.0039 in)
Drive pinion shim
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
32295AA0310.150
(0.0059) 32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069) 32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079) 32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089) 32295AA1010.500
(0.0197)
Main shaft rear plate
Dimension “A” mm (in) Part No. Mark
4.00 — 4.13
(0.1575 — 0.1626) 32294AA041 1
3.87 — 3.99
(0.1524 — 0.1571) 32294AA051 2
Snap ring (Outer-19)
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
Dimension “D” mm (in) Number of shim
52.50 — 53.11
(2.0669 — 2.0909)—
52.00 — 52.49
(2.0472 — 2.0665)1
51.26 — 51.99
(2.0181 — 2.0468)2
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
Snap ring (Inner-68)
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
Snap ring (Outer-25)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)

5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH)
wall clearance :
6.0 — 7.5 mm (0.236 — 0.295 in)
After installing a suitable reverse shifter lever, ad-
just the clearance using washers.
Reverse idler gear to transmission case wall
clearance:
0 — 0.5 mm (0 — 0.020 in)
8. SHIFTER FORK AND ROD
Select the suitable shifter forks so that both cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance :
A: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
B: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
9. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Reverse check plate adjustment
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall
Washer (20.5×26×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059) — —
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3 Approach to 2nd gear
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3 Approach to 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA211 No mark Standard
32812AA221 9Become distant from
5th gear by 0.2 mm
(0.008 in)
5th shifter fork (Turbo)
Part No. Mark Remarks
32812AA231 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in)
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA130 SNeutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 UNeutral position is
closer to reverse gear.
Reverse check plate
Par t No. Mar kAngle
θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.

5MT-5
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
10.EXTENSION ASSEMBLY
Thrust washer (50×61×t) to taper roller bearing
table outer race side clearance :
0.2 — 0.3 mm (0.0008 — 0.012 in)
NOTE:
Be sure to set within the standard clearance.
Thrust washer to center differential side
clearance :
0.15 — 0.35 mm (0.0059 — 0.0138 in)
11.FRONT DIFFERENTIAL
Bevel gear to pinion backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
12.TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clear-
ance :
0.01 — 0.15 mm (0.0004 — 0.0059 in)
Thrust 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)
Thrust 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)
Washer (38.1×50×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
8030380210.925 —
0.950
(0.0364 —
0.0374)8030380231.025 —
1.050
(0.0404 —
0.0413)
8030380220.975 —
1.000
(0.0384 —
0.0394)——
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)

5MT-6
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
B: COMPONENT
1. TRANSMISSION CASE
MT-00002
T(3) (1)
(2)
(4) (5)
(12) (10) (11)
(18)
(13)
(9)
(8)
(7)
(6)
(16) (14)
(15)(17)

5MT-7
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
 Transmission case tightening torque
(1) Transmission case ASSY (Single-
range)(9) Oil seal (16) High-low cable bracket A (Dual-
range)
(10) Clamp
(2) Gasket (11) Pitching stopper bracket (17) High-low cable bracket B (Dual-
range)
(3) Drain plug (12) Clip
(4) Snap ring (Outer) (13) Oil level gauge (Non-turbo model) (18) Oil level gauge (Turbo model)
(5) Speedometer driven gear (14) Oil seal (Dual-range)
(6) Washer (15) Transmission case ASSY (Dual-
range)Tightening torque: N·m (kgf-m, ft-lb)
(7) Speedometer shaftT: 44 (4.5, 32.5) (Aluminum gasket)
(8) Snap ring (Outer)70 (7.1, 51.6) (Copper gasket)
Bolt No. Bolt sizeTightening torque:
N·m (kgf-m, ft-lb)
<5> to <15> 8 mm 25 (2.5, 18.1)
<1> to <4>
<16>, <17> 10 mm 39 (4.0, 28.9)
MT-00003

5MT-8
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. DRIVE PINION ASSEMBLY
(1) Drive pinion shaft (14) 1st driven gear (28) Lock washer
(2) Roller bearing (15) Baulk ring (29) Lock nut
(3) Washer (16) 1st-2nd synchronizer hub (30) Washer
(4) Thrust bearing (17) Insert key (31) Thrust bearing
(5) Needle bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(6) Driven shaft (19) Outer baulk ring (33) Washer
(7) Key (20) Synchro cone (34) Lock washer
(8) Woodruff key (21) Inner baulk ring (35) Lock nut
(9) Drive pinion collar (22) 2nd driven gear
(10) Needle bearing (23) 2nd driven gear bushTightening torque: N·m (kgf-m, ft-lb)
(11) Snap ring (Outer) (Non-turbo
model)(24) 3rd-4th driven gearT1: 30 (3.1, 22.1)
(25) Driven pinion shimT2: 120 (12.2, 88.5)
(12) Washer (Non-turbo model) (26) Roller bearingT3: 260 (26.5, 192)
(13) Sub gear (Non-turbo model) (27) 5th driven gear
MT-00004
(5)
(4)
(1)
(25)(26)(27) (28)(29)
(21)(22)(23)
(31)(30)(32)(33)(34) (24)
(20)(18)
(19)(6)(3)
(2)
(12) (11)
(10)
(9) (8)
(7)
(13)(16)(17)
(14)(15)
T1
T3
(35)T2
(30)