differential SUBARU FORESTER 2004 Service Repair Manual

5MT-46
MANUAL TRANSMISSION AND DIFFERENTIAL
Vehicle Speed Sensor
8. Vehicle Speed Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Remove the front, center and rear exhaust pipe
and muffler.
4) Disconnect the connector from vehicle speed
sensor.
5) Turn and remove the vehicle speed sensor.
B: INSTALLATION
NOTE:
 Discard the vehicle speed sensor and after re-
moval, replace with a new one.
 Ensure the sensor mounting hole is clean and
free of foreign matter.
 Align the tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tool.
Tightening torque:
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front and center exhaust pipe.
5) Lower the vehicle.
6) Connect the battery ground cable to battery.
C: INSPECTION
Inspect the vehicle speed sensor.
SPEED SENSOR CIRCUIT LOW INPUT, Diagnos-
tic Procedure with Diagnostic Trouble Code
(DTC).> HICLE SPEED SENSOR CIRCUIT HIGH INPUT,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
MT-00113

5MT-47
MANUAL TRANSMISSION AND DIFFERENTIAL
Preparation for Overhaul
9. Preparation for Overhaul
A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove the drain plug to drain oil.
3) Tighten the drain plug using new gasket.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-
ket)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
4) Remove the outlet pipe. (model with oil pump)
5) Attach the transmission to ST.
ST 499937100 TRANSMISSION STAND
6) Rotating parts should be coated with oil prior to
assembly.
7) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.8) Gaskets, lock washers and lock nut must be re-
placed with new ones.
9) Liquid gasket should be used where specified to
prevent leakage.
(A) Outlet pipe
MT-00097
MT-00369
MT-00115
ST

5MT-48
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Pump
10.Oil Pump
A: REMOVAL
For extension case removal procedure, refer to
“Transfer Case and Extension Case Assembly”.
Extension Case Assembly.>
B: INSTALLATION
For extension case installation procedure, refer to
“Transfer Case Pump and Extension Case Assem-
bly”. Case and Extension Case Assembly.>
C: DISASSEMBLY
1) Remove the transfer drive gear assembly. to 5MT-54, REMOVAL, Transfer Drive Gear.>
2) Remove the oil strainer from extension case.
3) Remove the shift bracket.
4) Remove the relief valve from extension case.5) Remove the oil pump cover from extension.
6) Remove the rotor assembly, oil pump shaft and
O-ring.
D: ASSEMBLY
1) Install the rotor assembly and oil pomp shaft to
extension case.
2) Install a new O-ring to oil pump cover.
NOTE:
Apply a coat of gear oil to the O-ring.
3) Install the oil pump cover to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-00370
MT-00371
MT-00372
(A) Oil pump cover
(A) Oil pump shaft
(B) Rotor ASSY
(C) O-ring
(A) Oil pump cover
MT-00373
MT-00374
MT-00373

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. 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. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition 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. 5MT-59, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. to 5MT-54, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
3) Remove the oil seal from extension case. 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. 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.
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. 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. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. es and Harness.>
3) Remove the transfer case with extension case
assembly. 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. fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>6) Install the manual transmission assembly to ve-
hicle. 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. 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