SUBARU FORESTER 2004 Service Repair Manual

5MT-49
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Pump
4) Install a new O-ring, relief valve and return
spring to extension case.
Tightening torque:
12.75 N·m (1.3 kgf-m, 9.4 ft-lb)
5) Install the shift bracket to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
6) Install the oil strainer to extension case.
Tightening torque:
26 N·m (2.7 kgf-m, 19 ft-lb)
7) Install the transfer drive gear. <Ref. to 5MT-54,
INSTALLATION, Transfer Drive Gear.>E: INSPECTION
Use a thickness gauge to measure the chip clear-
ance of the rotor assembly. If the value exceeds
standard, replace the rotor as an assembly.
Chip clearance:
Less than 0.15 mm (0.0059 in)
MT-00375
MT-00371
MT-00370
MT-00376

5MT-50
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
11.Transfer Case and Extension
Case Assembly
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-43, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly.
4) Remove the shifter arm.
5) Remove the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.2) Remove the bearing outer race from extension
case.
3) While pressing the bearing outer race horizontal-
ly, turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
5) Measure the depth “X”.
NOTE:
Measure with bearing cone and thrust washer re-
moved.
6) Calculate the space “t” using the following equa-
tion: t = X−W+0.2 to 0.3 mm (0.008 to 0.012 in)
7) Select the nearest washer in the following table:
Standard clearance between thrust washer and
taper roller bearing:
0.2 — 0.3 mm (0.008 — 0.012 in)
NOTE:
Set the clearance within standard clearance.
MT-00116
MT-00117
MT-00118
(A) Bearing outer race
(B) Extension case
MT-00119
(B)
(A)
MT-00120
W
MT-00121
X

5MT-51
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
8) Fit the thrust washers on transfer drive shaft.
9) Install the bearing outer race into extension
case.
10) Measure the depth “S” between transfer case
and center differential.
ST 398643600 GAUGE
11) Measure the depth “T” between extension case
and transfer drive gear.
ST 398643600 GAUGE12) Calculate the space “U” using the following
equation: U = S+T−30 mm (1.18 in) [Thickness of
ST]
13) Select the suitable washer in the following ta-
ble:
Standard clearance:
0.15 — 0.35 mm (0.0059 — 0.0138 in)
14) Fit the thrust washer on center differential.
15) Apply proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. : 004403007)
16) Install the extension assembly into transfer
case.
Tightening torque:
40 N·m (4.1 kgf-m, 30 ft-lb)
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)
MT-00122
ST
S
MT-00123
T
ST
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)
MT-00124
MT-00117

5MT-52
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
17) Install the shifter arm to transfer case.
18) Hang the shifter arm on 3rd-4th fork rod.
19) Install the transfer case with extension case as-
sembly to transmission case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
5MT-59, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to 5MT-54, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
3) Remove the oil seal from extension case. <Ref.
to 5MT-41, REPLACEMENT, Oil Seal.>
(A) Shifter arm
(B) 3rd-4th fork rod
MT-00126
MT-00127
(A)
(B)
MT-00116
MT-00129
MT-00130

5MT-53
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, insert the new oil seal to extension
case. <Ref. to 5MT-41, REPLACEMENT, Oil
Seal.>
2) Install the shift bracket to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Install the transfer drive gear to extension case.
<Ref. to 5MT-54, INSTALLATION, Transfer Drive
Gear.>
2. TRANSFER CASE
1) Install the oil guide to transfer case.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
2) Install the reverse check sleeve assembly to
transfer case. <Ref. to 5MT-59, INSTALLATION,
Reverse Check Sleeve.>
MT-00130
MT-00129

5MT-54
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
12.Transfer Drive Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-43, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-50, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
26 N·m (2.7 kgf-m, 20 ft-lb)
2) Install the transfer driven gear.
3) Install the extension case assembly.
4) Install the transfer case and extension case as-
sembly. <Ref. to 5MT-50, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. <Ref. to 5MT-44, INSTALLATION,
Switches and Harness.>6) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-36, INSTALLATION, Manual
Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring.
2) Remove the ball bearing.
D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
install to drive shaft.
ST 398177700 INSTALLER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
2) Install the snap ring on transfer drive shaft.
3) Check the clearance between snap ring and ball
bearing. <Ref. to 5MT-55, INSPECTION, Transfer
Drive Gear.>
MT-00133
MT-00133
MT-00135
MT-00136
MT-00137
ST

5MT-55
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
 Broken or rusty bearings
 Worn or damaged
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
2) Drive gear
Replace the drive gear in the following cases:
 If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
If the measurement is not within specification, se-
lect a suitable snap ring.
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-00138

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

5MT-56
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Driven Gear
13.Transfer Driven Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-43, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-50, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the bearing outer race from extension
case and transfer case.
B: INSTALLATION
1) Install the bearing outer race to extension case
and transfer case.
2) Install the transfer driven gear.
3) Install the transfer case and extension case as-
sembly. <Ref. to 5MT-50, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
4) Install the back-up light switch and neutral posi-
tion switch. <Ref. to 5MT-44, INSTALLATION,
Switches and Harness.>
5) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-36, INSTALLATION, Manual
Transmission Assembly.>
(A) Bearing outer race (transfer case)
(B) Bearing outer race (extension case)
MT-00118
MT-00140 (B)
(A)
(A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension case
(C)
(A)
(D)(B)
MT-00141
MT-00118

5MT-57
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Driven Gear
C: DISASSEMBLY
1) Using the ST, remove the roller bearing (exten-
sion case side).
ST 498077000 REMOVER
2) Using the ST1 and ST2, remove the roller bear-
ing (transfer case side).
ST1 498077000 REMOVER
ST2 899864100 REMOVER
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension
case side).
ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
2) Using the ST, install the roller bearing (transfer
case side).
ST 499757002 INSTALLER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
 Broken or rusty bearings
 Worn or damaged
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
2) Driven gear
Replace the drive gear in the following cases:
 If their tooth surfaces and shaft are excessively
broken or damaged.
(A) Roller bearing
(A) Roller bearing
MT-00143
(A)ST
MT-00144
(A)
ST1
ST2
(A) Roller bearing
(A) Roller bearing
MT-00145
(A)ST1
ST2
(A)
MT-00146
ST