SUBARU FORESTER 2004 Service Repair Manual
Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2781 of 2870
5MT-68
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
16) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
17) Inspect and adjust the backlash and tooth con-
tact of hypoid gear.
18) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit the O-
ring into groove and tighten the retainer into the po-
sition where retainer has been tightened in.
Tighten the lock plate.
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
19) Selection of main shaft rear plate
gle-Range.>
20) Install the transfer case with extension case as-
sembly.
21) Install the clutch release lever and bearing.
22) Install the manual transmission assembly into
the vehicle.
Check the transmission case for cracks, damage,
and oil leaks.
MT-00177
T
Page 2782 of 2870
5MT-69
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
17.Main Shaft Assembly For Sin-
gle-Range
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle.
2) Remove the transfer case with extension case
assembly.
3) Remove the transmission case.
Assembly.>
4) Remove the drive pinion shaft assembly.
bly.>
5) Remove the main shaft assembly.
B: INSTALLATION
1) Wrap the clutch splined section with vinyl tape to
prevent damage to oil seal.
2) Apply grease Unilube #2 (or equivalent) to the
sealing lip of oil seal.
3) Install the needle bearing and new oil seal onto
the front of transmission main shaft assembly.
4) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
5) Install the drive pinion assembly.
bly.>
6) Install the transmission case.
7) Install the transfer case with extension case as-
sembly.
8) Install the manual transmission assembly to ve-
hicle.
C: DISASSEMBLY
1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
NOTE:
Unlock the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3) Remove the 5th-Rev sleeve and hub assembly,
5th baulk ring, 5th drive gear and needle bearing.
4) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
MT-00185
(A)
(A) 5th-Rev sleeve and hub ASSY
(B) 5th baulk ring
(C) 5th drive gear
(A) Synchro cone stopper
(B) Snap ring
MT-00186ST2ST1
MT-00187
(A) (B) (C)
MT-00188
(A) (B)
Page 2783 of 2870
5MT-70
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
5) Using the ST1, ST2 and a press, remove the ball
bearing, synchro cone and baulk ring (Rev).
NOTE:
If replace the sleeve or hub assembly as neces-
sary, use the new sleeve & hub assembly as a unit.
Do not disassemble because they must engage at
a specified point. If they should be disassembled,
mark engagement point on splines beforehand.
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOV-
ER6) Using the ST1 and ST2, remove rest of the
parts.
NOTE:
If replace the sleeve or hub assembly as neces-
sary, use the new sleeve & hub assembly as a unit.
Do not disassemble because they must engage at
a specified point. If they should be disassembled,
mark engagement point on splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
(A) Ball bearing
(B) Revers synchro cone
(C) Revers baulk ring
MT-00189
(B)
(A)
(C)ST2
ST1
(A) Press
MT-00190
(A)
ST2
ST1
Page 2784 of 2870
5MT-71
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
D: ASSEMBLY
1. NON-TURBO MODEL
1) Assemble each sleeve and hub assembly.
2) Install the 3rd drive gear, outer baulk ring, 3rd
synchro cone, inner baulk ring, 3rd-4th sleeve and
hub assembly for 3rd needle bearing on transmis-
sion main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4) Install the 4th baulk ring, 4th needle bearing, 4th
drive gear and 4th gear thrust washer to transmis-
sion main shaft.
NOTE:
Align the baulk ring and gear & hub assembly
with key convex part.
Pay attention to the orientation of thrust washer.
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th-Rev hub ASSY
(D) 5th gear side
MT-00191 (D) (C)(B) (A)
(A) 4th needle bearing race
(A) Groove
(B) Face this surface to 4th gear side
MT-00192 (A)
ST1
ST2
MT-00193 (A)
(B)
Page 2785 of 2870
5MT-72
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
5) Drive the ball bearing onto the rear section of
transmission main shaft using ST1, ST2 and a
press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6) Using the ST1 and ST2, install the 5th gear
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Pay attention to the orientation of thrust washer.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7) Install the bearing onto synchro cone.
8) Install the Rev baulk ring, Rev synchro cone and
new ball bearing. onto 5th-Rev sleeve and hub as-
sembly using ST and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).9) After press fitting, make sure the synchro cone
rotates freely.
ST 499757002 INSTALLER
10) Install the synchro cone stopper and snap ring
to 5th-Rev sleeve and hub assembly.
(A) Face this surface to 5th gear side.
MT-00194
ST1
ST2
MT-00195
(A)
(A) Rev Baulk ring
(B) Rev Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
(B) (A)
(C)
ST
MT-00188
(A) (B)
Page 2786 of 2870
5MT-73
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 2. TURBO MODEL
1) Assemble each sleeve and hub assembly.
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on transmission main
shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
(A) 5th needle bearing
(B) 5th drive gear
(C) 5th baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th-Rev hub ASSY
(D) 5th gear side
(A) 3rd needle bearing
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
MT-00191 (D) (C)(B) (A)
MT-00200
(A)
(B)
(C) (D)(E)
(F)
Page 2787 of 2870
5MT-74
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4) Install the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly
with key convex part.
Pay attention to the orientation of thrust washer.5) Drive the ball bearing onto the rear section of
transmission main shaft using ST1, ST2 and a
press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6) Using the ST1 and ST2, install the 5th gear
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Pay attention to the orientation of thrust washer.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7) Install the bearing onto synchro cone.
8) Install the baulk ring, synchro cone and new ball
bearing. onto 5th-Rev sleeve and hub assembly
using ST and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
(A) 4th needle bearing race
(A) Groove
(B) Face this surface to 4th gear side
MT-00192 (A)
ST1
ST2
MT-00193 (A)
(B)
(A) Face this surface to 5th gear side.
MT-00194
ST1
ST2
MT-00195
(A)
Page 2788 of 2870
5MT-75
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
9) Make sure the synchro cone rotates smoothly af-
ter press-fitting.
ST 499757002 INSTALLER
10) Install the synchro cone stopper and snap ring
to 5th-Rev sleeve and hub assembly.11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
(B) (A)
(C)
ST
MT-00188
(A) (B)
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
Page 2789 of 2870
5MT-76
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are dam-
aged.
When the ring inner surface is abnormally or par-
tially worn down.
When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
F: ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bear-
ing protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
ST 498147000 DEPTH GAUGE
MT-00208
Dimension (A)
mm (in)Par t No. Mar k
4.00 — 4.13
(0.1575 —
0.1626)32294AA041 1
3.87 — 3.99
(0.1524 —
0.1571)32294AA051 2
MT-00209
(A)
Page 2790 of 2870
5MT-77
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Dual-Range
18.Main Shaft Assembly For
Dual-Range
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle.
2) Remove the transfer case with extension case
assembly.
3) Remove the transmission case.
4) Remove the drive pinion shaft assembly.
bly.>
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION
1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Select the input shaft adjusting shim and install it
to the input shaft assembly.
3) Connect the main shaft assembly and input shaft
assembly.
4) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
5) Install the drive pinion assembly.
bly.>
6) Install the transmission case.
7) Install the transfer case with extension case as-
sembly.
8) Install the manual transmission assembly to ve-
hicle.
C: DISASSEMBLY
1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove caulking of the lock nut.
3) Remove the lock nut from transmission main
shaft assembly.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
4) Remove the 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing.
5) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
(A) Synchro cone stopper
(B) Snap ring
MT-00186ST2ST1
MT-00187
(A) (B) (C)
MT-00188
(A) (B)