SUBARU FORESTER 2004 Service Repair Manual

5MT-9
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. MAIN SHAFT ASSEMBLY (SINGLE RANGE)
(1) Oil seal (15) Needle bearing (28) Rev synchro cone
(2) Needle bearing (16) 4th gear thrust washer (29) Ball bearing
(3) Transmission main shaft (17) Double taper roller bearing (30) Synchro cone stopper
(4) Needle bearing (18) 5th gear thrust washer (Non-turbo
model)(31) Snap ring
(5) 3rd drive gear (32) Lock washer
(6) Inner baulk ring (19) 5th needle bearing race (33) Lock nut
(7) 3rd synchro cone (20) Needle bearing (34) Reverse idler gear shaft
(8) Outer baulk ring (21) Main shaft rear plate (35) Straight pin
(9) 3rd-4th coupling sleeve (22) 5th drive gear (36) Reverse idler gear
(10) 3rd-4th synchronizer hub (23) 5th baulk ring (37) Washer
(11) 3rd-4th shifting insert key (24) 5th-Rev shifting insert key
(12) 4th baulk ring (25) 5th-Rev synchronizer hubTightening torque: N·m (kgf-m, ft-lb)
(13) 4th drive gear (26) 5th-Rev coupling sleeveT: 120 (12.2, 88.5)
(14) 4th needle bearing race (27) Rev baulk ring
T
(18)
(19)(20)(21)(22)(23) (24)
(25)(26)(27)(28)(29)(30)(31)(32)(33)
(35)(34)(36)
(37)
(3)
(9)(10)
(4)(5) (2)
(1)
(6)(7)(8)(11)(17)
(12)(13)(14)(15)(16)
MT-00005

5MT-10
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
4. MAIN SHAFT ASSEMBLY (DUAL RANGE)
MT-01014
(3) (4)(4)
T2
T3
T1
T4
(5)
(2)
(1)(6)(6)
(7)
(8)
(9)(10)
(11)(17)(18)(19)(20)
(21)(22)
(23)(30)(31)(32)(33)
(34)(34)
(35)(35)
(37)(36)
(49)(50)(51)(52)(53)(54) (55)
(56)(57)(58)(59)(60)(61)(62)(63)(64)
(66) (69)
(70)
(71)(72)
(73)
(74)
(75)
(76)(77)(78)
(79)
(80)
(65)(67)(68) (38)(40)
(39)(40)(41)(42)(43)(44)(45)(46)(47)(48) (29) (12)(13) (14)
(15) (16)
(28)
(27) (26)
(25)
(24)(24)

5MT-11
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
(1) O-ring (30) Needle bearing (59) Rev synchro cone
(2) High-low counter shaft (31) Input low gear spacer (60) Ball bearing
(3) Knock pin (32) Ball (61) Synchro cone stopper
(4) High-low counter washer (33) Main shaft (62) Snap ring
(5) Counter gear (34) Needle bearing (63) Lock washer
(6) Needle bearing (35) 3rd drive gear (64) Lock nut
(7) Counter gear collar (36) 3rd baulk ring (2.0L model) (65) Reverse idler gear shaft
(8) Snap ring (Outer-19) (37) Inner baulk ring (2.5L model) (66) Straight pin
(9) Input shaft holder (38) 3rd synchro cone (2.5L model) (67) Reverse idler gear
(10) Input shaft shim (39) Outer baulk ring (2.5L model) (68) Washer
(11) Oil seal (40) 3rd-4th coupling sleeve (69) Straight pin
(12) O-ring (41) 3rd-4th synchronizer hub (70) High-low shifter lever
(13) Snap ring (Outer-28) (42) 3rd-4th shifting insert key (71) High-low shifter shaft
(14) Oil squeeze (43) 4th baulk ring (72) Low switch
(15) Straight pin (44) 4th drive gear (73) Gasket
(16) Snap ring (Outer-28) (45) 4th needle bearing race (74) Straight pin
(17) Ball bearing (46) Needle bearing (75) High-low shifter fork
(18) Snap ring (Inner-68) (47) 4th gear thrust washer (76) High-low shifter piece
(19) Input shaft (48) Ball bearing (77) Ball
(20) Needle bearing (49) 5th gear thrust washer (78) Spring
(21) Snap ring (Outer-25) (50) 5th needle bearing race (79) Gasket
(22) High-low baulk ring (51) Needle bearing (80) Plug
(23) High-low coupling sleeve (52) Main shaft rear plate
(24) High-low synchronizer spring (53) 5th drive gearTightening torque: N·m (kgf-m, ft-lb)
(25) High-low synchronizer hub (54) 5th baulk ringT1: 9.75 (0.99, 7.2)
(26) Shifting insert key (55) 5th-Rev shifting insert keyT2: 20 (2.0, 14.5)
(27) High-low baulk ring (56) 5th-Rev synchronizer hubT3: 25 (2.5, 18.1)
(28) Friction damper (57) 5th-Rev coupling sleeveT4: 120 (12.2, 88.5)
(29) Input low gear (58) Rev baulk ring

5MT-12
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
5. SHIFTER FORK AND SHIFTER ROD
(1) Shifter arm (8) Ball (15) Spring
(2) 5th shifter fork (9) 3rd-4th fork rod (16) Snap ring (Outer)
(3) Straight pin (10) Interlock plunger (17) Reverse fork rod arm
(4) Reverse fork rod (11) 1st-2nd fork rod (18) Reverse shifter lever
(5) Checking ball plug (12) 3rd-4th shifter fork
(6) Gasket (13) 1st-2nd shifter forkTightening torque: N·m (kgf-m, ft-lb)
(7) Checking ball spring (14) BallT: 20 (2.0, 14.5)
MT-00007
T
T
T (1)
(2)
(3)
(3)(3) (4)
(5)
(5)
(5) (6)
(6) (6) (7)
(7)
(7) (8)
(8)(8)(9)
(10)(10)
(10)
(11) (12)
(13) (14) (15) (16)(17)(18)

5MT-13
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
6. TRANSFER CASE AND EXTENSION (WITHOUT OIL PUMP MODEL)
(1) Oil guide (16) Return spring (31) Transfer drive gear
(2) Gasket (17) O-ring (32) Ball bearing
(3) Transfer case (18) Adjusting select shim (33) Extension case
(4) Ball (19) Reverse check sleeve (34) Oil seal
(5) Reverse accent spring (20) Gasket (35) Dust cover
(6) Gasket (21) Neutral switch (36) Shift bracket
(7) Plug (22) Gasket (37) Snap ring
(8) Oil seal (23) Back-up light switch
(9) Snap ring (Inner) (24) Roller bearingTightening torque: N·m (kgf-m, ft-lb)
(10) Reverse check plate (25) Transfer driven gearT1: 6.4 (0.65, 4.7)
(11) Reverse check spring (26) Roller bearingT2: 9.75 (1.0, 7.2)
(12) Reverse return spring (27) Adjusting washerT3: 24.5 (2.5, 18.1)
(13) Reverse check cam (28) Ball bearingT4: 26 (2.7, 20)
(14) Reverse accent shaft (29) Center differentialT5: 40 (4.1, 30)
(15) Return spring cap (30) Adjusting washer
MT-00008
(2)(7)
(6)
(21) (8) (5)
(4)
(3)
(1)
T3 T2
T3
T3
T1
T1
(20)
(9)
(11)
(13)(15) (10)(12)
(17)
(16)(19)
(22)(23)
(14)
(18)
T3
T5
T4(34)
(36) (35)
(33) (27)
(31)(30)
(29)
(28)
(37)
(32)
(24)(25)(26)
T3T5

5MT-14
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. TRANSFER CASE AND EXTENSION (WITH OIL PUMP MODEL)
(1) Oil guide (20) O-ring (39) Snap ring
(2) Gasket (21) Adjusting select shim (40) Ball bearing
(3) Transfer case (22) Reverse check sleeve (41) Transfer drive gear
(4) Ball (23) Shift bracket (42) Washer
(5) Reverse accent spring (24) Oil pump cover (43) Center differential
(6) Gasket (25) O-ring (44) Ball bearing
(7) Plug (26) Oil pump shaft (45) Adjusting washer
(8) Oil seal (27) Inner rotor (46) Roller bearing
(9) Gasket (28) Outer rotor (47) Transfer driven gear
(10) Neutral switch (29) Relief valve (48) Roller bearing
(11) Back-up light switch (30) Return spring
(12) Snap ring (Inner) (31) O-ringTightening torque: N·m (kgf-m, ft-lb)
(13) Reverse check spring (32) Dust coverT1: 6.4 (0.65, 4.7)
(14) Reverse check spring (33) Oil sealT2: 9.75 (1.0, 7.2)
(15) Reverse check cam (34) Outlet pipeT3: 12.75 (1.3, 9.4)
(16) Return spring (35) GasketT4: 24.5 (2.5, 18.1)
(17) Reverse accent shaft (36) Extension caseT5: 26 (2.7, 20)
(18) Return spring cap (37) Oil strainerT6: 40 (4.1, 30)
(19) Return spring (38) Straight pin
MT-00368
(2)(7)
(6)
(10) (8) (5)
(4)
(3)
(1)
T4
T4
T2
T4
T4
(11)
T4
T4
T3
T3
T6
T6
T5
T5
T1
T1
(9)
(12)(14)
(15)(18)
(13)(16)
(20)
(19)(22)
(33)
(23)
(24) (32)
(25)
(26)
(27)
(28)
(36)
(31) (30) (29)
(37)
(35)
(9)(17)
(45)
(41)
(42)
(43)
(44)
(39)
(38)(40)
(21)
(48)(47)(46)(34)

5MT-15
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
8. FRONT DIFFERENTIAL
(1) Drive pinion shaft (7) Differential bevel pinion (13) Retainer lock plate
(2) Hypoid driven gear (8) Roller bearing
(3) Pinion shaft (9) Differential caseTightening torque: N·m (kgf-m, ft-lb)
(4) Straight pin (10) Oil sealT1: 25 (2.5, 18.1)
(5) Washer (11) Differential side retainerT2: 62 (6.3, 45.6)
(6) Differential bevel gear (12) O-ring
MT-00009
(12)(10)
(1)
(2)
T1
T2
(5)
(5)
(6)
(9)
(7)
(7)
(12) (8)
(8)
(13)
(13)(11)
(11) (10)
T1
(4)(3)

5MT-16
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
9. TRANSMISSION MOUNTING
(1) Pitching stopper (8) Cushion DTightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmemberT1: 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plateT2: 35 (3.6, 26)
(4) Front plate (11) Front crossmemberT3: 50 (5.1, 36.9)
(5) Dynamic damperT4: 58 (5.9, 43)
(6) Rear cushion rubberT5: 70 (7.1, 51)
(7) Rear crossmemberT6: 140 (14.3, 103)
(1)
T4
T1
T5
T5
T5
T2
T6
T2
T3
(2)
(4)
(6)
(8)
(9)
(8)(3)
(2)
(10)
(7)
(5)
(3)
(11)
MT-00010

5MT-17
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation, and disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
 Be careful not to burn your hands, because each
part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply gear oil onto sliding or revolution surfaces
before installation.
 Replace deformed or otherwise damaged snap
rings with new ones.
 Before installing O-rings or oil seals, apply suffi-
cient amount of gear oil to avoid damage and defor-
mation.
 Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vis e.
 Avoid damaging the mating surface of the case.
 Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
399411700 ACCENT BALL
INSTALLERUsed for installing reverse shifter rail arm.
899524100 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) PULLER
(2) CAP
ST-399411700
ST-899524100

5MT-18
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
399780104 WEIGHT Used for measuring preload on roller bearing.
498077000 REMOVER Used for removing roller bearing of drive pinion
shaft.
498077300 CENTER DIFFER-
ENTIAL BEARING
REMOVERUsed for removing the center differential cover
ball bearing.
498147000 DEPTH GAUGE Used for adjusting main shaft axial end play. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-399780104
ST-498077000
ST-498077300
ST-498147000