SUBARU FORESTER 2004 Service Repair Manual

5MT-108
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
4) Inspect the clearance between 3rd, 4th drive
gear and coupling sleeve. If any clearance is not
within specifications, replace the shifter fork as re-
quired.
Clearance (a) and (b):
9.3 mm (0.366 in)
5) Inspect the clearance between 5th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in) 6) Inspect the rod end clearances (A) and (B). If
any clearance is not within specifications, replace
the rod or fork as required.
Clearance (A):
1st-2nd to 3rd-4th:
0.4 — 1.4 mm (0.016 — 0.055 in)
Clearance (B):
3rd-4th to 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
(A) 3rd drive gear
(B) Coupling sleeve
(C) 4th drive gear
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in).
32810AA071 — Standard
32810AA101 3Approach to 3rd gear
by 0.2 mm (0.008 in).
(A) 5th drive gear
(B) Coupling sleeve
MT-00940
(A)(B)
(C) (a) (b)
MT-00315
(A)(B) (a)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in).
32812AA211 — Standard
32812AA221 9Approach to 5th gear
by 0.2 mm (0.008 in).
5th shifter fork (Turbo)
Part No. Mark Remarks
32812AA231 7Approach to 5th gear
by 0.2 mm (0.008 in).
32812AA241 — Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in).
MT-00379
(B)(A)

5MT-109
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
25.Counter Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
3) Remove the transmission case. 62, REMOVAL, Transmission Case.>
4) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.
5) Slide the washer at rear of high-low counter
shaft, and remove the straight pin from counter
shaft.6) Remove the counter shaft from transmission
case, taking care not to drop the counter gear and
two washers.
NOTE:
 Be careful not to damage the O-ring.
 Be careful not to drop the straight pin on front
side.
 Be careful not to drop the two needle bearings
and collar contained in counter gear.
B: INSTALLATION
1) Install the O-ring and straight pin onto counter
gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
 Counter gear shaft
 Two counter gear washers
 Two needle bearings
 Counter gear collar
 Counter gear
 Straight pin
 Snap ring
3) Install the transmission case. INSTALLATION, Transmission Case.>
4) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the manual transmission assembly on ve-
hicle. Transmission Assembly.>
NOTE:
 Make sure that the cut-out end surface of counter
gear shaft does not protrude above the end surface
of the case.
 Position the cut-out portion of counter gear shaft
as shown in the figure.(A) Snap ring
(A) Straight pin
(B) Counter gear
MT-00317
(A)
MT-00318(A)
(B)
(A) Counter shaft
(B) Counter gear
(C) Washers
MT-00319
(A)
(B)(C)

5MT-110
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
C: INSPECTION
1) After installing the snap ring, measure the clear-
ance between snap ring and counter washer.
Clearance:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
2) If the clearance is out of measured value, select
a snap ring and install to put clearance within mea-
sured value. Counter Gear.>
D: ADJUSTMENT
Selection of snap ring:
If the measurement is not within specification, se-
lect suitable snap ring.
Snap ring
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)

5MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
26.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
N
OTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gearReplace.
(b) Worn, damaged or burred chamfer of
spline of gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wear Correct or replace.
2. Gear slips out.
 Gear slips out when coasting on rough
road.
 Gear slips out during acceleration.(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail springReplace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeveReplace.
(f) Worn tooth step of synchronizer hub Replace.
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and 2nd bush Replace.
(i) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis-
sion.
N
OTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.Replace.

5MT-112
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
2. DIFFERENTIAL
Symptom Possible cause Remedy
1. Broken differential (case, gear, bear-
ing, etc.)
N
OTE:
Noise will develop and finally it will be-
come impossible to continue to run due to
broken pieces obstructing the gear revo-
lution. (a) Insufficient or improper oil Disassemble the differential and replace
broken components and at the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutch Readjust the bearing preload and back-
lash and face contact of gears.
(c) Improper adjustment of taper roller
bearingAdjust.
(d) Improper adjustment of drive pinion
and hypoid driven gear Adjust.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions. Add recommended oil to specified level.
Do not use the vehicle under severe oper-
ating conditions.
(f) Loose hypoid driven gear clamping
boltsTighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas, bear-
ing, body, etc. are easily mistaken for the
differential noise. Pay special attention to
the hypoid gear noise because it is easily
confused with other gear noises. There
are the following four kinds of noises.
 Gear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
 Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
 Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
 Noise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc. (a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinionReplace as a set.
Readjust the bearing preload.
(d) Loose roller bearing Readjust the hypoid driven gear to drive
pinion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential caseReplace.
(f) Worn washer and differential pinion
shaftReplace.

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

CLUTCH SYSTEM
CL
Page
1. General Description ....................................................................................2
2. Clutch Disc and Cover ..............................................................................16
3. Flywheel ....................................................................................................19
4. Release Bearing and Lever.......................................................................20
5. Operating Cylinder ....................................................................................24
6. Master Cylinder .........................................................................................26
7. Clutch Pipe and Hose ...............................................................................29
8. Clutch Fluid ...............................................................................................31
9. Clutch Fluid Air Bleeding ...........................................................................32
10. Clutch Pedal ..............................................................................................34
11. Clutch Switch ............................................................................................41
12. General Diagnostic Table..........................................................................42

CL-2
CLUTCH SYSTEM
General Description
1. General Description
A: SPECIFICATION
I.D.: Inner diameter
O.D.: Outer diameter Model2.0 L Non-turbo,
2.5 L LHD2.0 L Turbo 2.5 L RHD 2.5 L Turbo
Clutch
coverType Push type Pull type Push type Pull type
Diaphragm set
loadkgf (lb) 580 (1,279) 700 (1,543) 580 (1,279) 800 (1,764)
Clutch
discFacing material Woven (Non asbestos)
O.D.×I.D.×Thic
knessmm (in)Flywheel
side
225×150×3.5
(8.86×5.91×0.138)230×155×3.5
(9.06×6.10×0.138)
Pressure
plate side
Spline O.D. mm (in) 25.2 (0.992), (No. of teeth: 24)
Clutch release lever ratio 1.6 1.7 1.6 1.7
Release bearing Grease-packed self-aligning
Clutch
pedalFull stroke mm (in) 130 — 135 (5.12 — 5.31)
Free play mm (in)4 — 12
(0.16 — 0.47)3 — 13
(0.12 — 0.51)4 — 12
(0.16 — 0.47)
Clutch
discDepth of rivet
head mm (in)Standard 1.3 — 1.9 (0.051 — 0.075)
Limit of sinking 0.3 (0.012)
Limit for run
outmm (in) 0.8 (0.031) at R = 110 (4.33) 1.0 (0.039) at R = 110 (4.33)

CL-3
CLUTCH SYSTEM
General Description
B: COMPONENT
1. CLUTCH ASSEMBLY
 NON-TURBO MODEL
(1) Clutch release lever dust cover (6) Clutch release bearingTightening torque: N⋅m (kgf-m, ft-lb)
(2) Retainer spring (7) Clutch coverT1: 16 (1.6, 11.6)
(3) Pivot (8) Clutch discT2: 72 (7.3, 52.8)
(4) Clutch release lever (9) Flywheel
(5) Clip
CL-00284
(4)
(2) (1)
(9)(5)
(6)
(7)
(8)(3)
(5)
T2
T1
T1

CL-4
CLUTCH SYSTEM
General Description
 TURBO MODEL
(1) Clutch release lever dust cover (5) Clutch release bearingTightening torque: N⋅m (kgf-m, ft-lb)
(2) Clutch release lever (6) Clutch coverT1: 16 (1.6, 11.6)
(3) Clutch release lever shaft (7) Clutch discT2: 44 (4.5, 32.5)
(4) Plug (8) FlywheelT3: 72 (7.3, 52.8)
CL-00002