SUBARU FORESTER 2004 Service Repair Manual

5MT-39
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Mounting System
4. Transmission Mounting Sys-
tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.
3) Remove the air intake duct. (Non-turbo model)

4) Remove the air cleaner case. (Non-turbo model)
Case.>
5) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
6) Remove the pitching stopper.
2. CROSSMEMBER AND CUSHION RUB-
BER
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle and support it with rigid
racks.
3) Remove the front and center exhaust pipes.
(Non-turbo model)
Pipe.>
haust Pipe.>
4) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped mod-
el)
7) Set the transmission jack under the transmission
body.
CAUTION:
Always support the transmission case with a
transmission jack. 8) Remove the rear crossmember.
9) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
2) Install the air intake duct and cleaner case.
(Non-turbo model)
Case.> Intake Duct.>
3) Install the intercooler. (Turbo model) IN(H4DOTC)-11, INSTALLATION, Intercooler.>
4) Connect the battery ground cable to battery.
AT-00023
MT-00079
AT-00025
T1
T2

5MT-40
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Mounting System
2. CROSSMEMBER AND CUSHION RUB-
BER
1) Install the rear cushion rubber.
Tightening torque:
35 N·m (3.6 kgf-m, 26 ft-lb)
2) Install the rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
3) Remove the transmission jack.
4) Install the heat shield cover. (If equipped model)
5) Install the front and center exhaust pipes. (Non-
turbo model)
haust Pipe.>
6) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
7) Install the rear exhaust pipe and muffler.
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfactory.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Make sure that the rubber is not stiff,
cracked or otherwise damaged.
2. CROSSMEMBER AND CUSHION RUB-
BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked or otherwise damaged.
MT-00081
T2T2
T1T1

5MT-41
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Seal
5. Oil Seal
A: INSPECTION
Check the oil seal portion for leakage. If leakage is
found, replace the oil seal with a new one.
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the gear oil completely.
3) Replace the gasket with a new one, and then
tighten the drain plug after draining gear oil.
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 rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped mod-
el)
6) Remove the propeller shaft. MOVAL, Propeller Shaft.>
7) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY8) Using the ST, install the oil seal.
ST 498057300 INSTALLER
9) Install the propeller shaft. STALLATION, Propeller Shaft.>
10) Install the heat shield cover. (If equipped mod-
el)
11) Install the rear exhaust pipe and muffler.
12) Pour gear oil and check the oil level. 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
(A) Oil seal
MT-00097
MT-00098
(A)ST
MT-00099

5MT-42
MANUAL TRANSMISSION AND DIFFERENTIAL
Differential Side Retainer Oil Seal
6. Differential Side Retainer Oil
Seal
A: INSPECTION
Check the differential side retainer oil seal for leak-
age of gear oil. If oil leaks, replace the oil seal.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Drain the gear oil from oil drain plug.
3) Replace the gasket with new one, and then tight-
en the differential oil drain plug.
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 front exhaust pipe and center ex-
haust pipe. (Non-turbo model) 7, REMOVAL, Front Exhaust Pipe.>
5) Separate the front drive shaft from transmission.

6) Using a vinyl tape, etc. wrapped flat tip screw-
driver, remove the differential side retainer oil seal.7) Using the ST, install the differential side retainer
oil seal tapping ST lightly with a hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
Be sure to apply oil to oil seal lip surface.
8) Install the front drive shaft. STALLATION, Front Drive Shaft.>
9) Install the front exhaust pipe and center exhaust
pipe. (Non-turbo model) STALLATION, Front Exhaust Pipe.>
10) Lower the vehicle.
11) Fill gear oil into the gauge hole. 31, REPLACEMENT, Transmission Gear Oil.>
(A) Drain plug
(A) Drain plug
(A)
MT-00339
(A)
MT-00339
MT-00103
ST

5MT-43
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
7. Switches and Harness
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.

Case.>
3) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
4) Disconnect the connector of back-up light switch
and neutral position switch.
 Non-turbo model
 Turbo model
5) Lift-up the vehicle.6) Remove the back-up light switch and neutral po-
sition switch with harness.
2. HIGH-LOW SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> to IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the connector of high-low switch.
4) Remove the high-low switch cable from clamp.
5) Remove the high-low switch.
(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
MT-00107
(B)
(C)
(A)
MT-00105
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
(A) Clamp
(B) High-low switch
MT-00106
(A)
(B)
MT-00107
(B)
(C)
(A)
MT-00108
(B)(A)

5MT-44
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
B: INSTALLATION
1. BACK-UP LIGHT SWITCH AND NEU-
TRAL POSITION SWITCH
1) Install the back-up light switch and neutral posi-
tion switch with harness.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Connect the connector of back-up light switch
and neutral position switch.
3) Install the air intake duct and cleaner case. to IN(H4SO)-7, INSTALLATION, Air Intake Duct.>
Case.>
4) Install the intercooler. (Turbo model)
cooler.>
5) Connect the battery ground cable to battery.
2. HIGH-LOW SWITCH
1) Install the high-low switch.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Install the high-low switch cable to clamp.
3) Connect the connector of high-low switch.
4) Install the air intake duct and cleaner case. to IN(H4SO)-7, INSTALLATION, Air Intake Duct.>
Case.>
5) Connect the battery ground cable to battery.
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
MT-00106
(A)
(B)

5MT-45
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch. SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model:
Turbo model:
 Non-turbo model
 Turbo model
4) Replace defective parts.
3. HIGH-LOW SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
4) Replace the defective parts.
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3Less than 1 Ω
Other positions More than 1 MΩ
MT-00110
1 2
MT-00111
1 2
3 4
Gear shift position Terminal No. Specified resistance
LO position
1 and 2Less than 1 Ω
HIGH position More than 1 MΩ
MT-00112
1 2

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