boot SUBARU FORESTER 2004 Service Owner's Manual

CS-17
CONTROL SYSTEM
MT Gear Shift Lever
5. MT Gear Shift Lever
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the gear shift knob.
3) Disconnect the ground cable from battery.
4) Remove the console box. MOVAL, Console Box.>
5) Remove the clamp.
6) Remove the boot & insulator assembly.
7) Remove the drive select cable. REMOVAL, Drive Select Cable.>
8) Remove the plate assembly from body.
9) Lift-up the vehicle.
10) Remove the rear exhaust pipe and muffler. Non-turbo model
Pipe.> fler.>
 Turbo model
haust Pipe.> AL, Muffler.>
11) Remove the heat shield cover. (If equipped)
12) Remove the stay from transmission bracket.
13) Remove the rod from joint.
14) Remove the cushion rubber from body.
CS-00099
CS-00100
CS-00101
(A) Stay
(B) Transmission bracket
(A) Stay
(B) Rod
(A) Stay
(B) Cushion rubber
CS-00050
(A)
(B)
CS-00051
(A)
(B)
CS-00052
(A)
(B)

CS-19
CONTROL SYSTEM
MT Gear Shift Lever
6) Connect the stay to transmission bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
7) Install the heat shield cover. (If equipped)
8) Install the rear exhaust pipe and muffler.
 Non-turbo model
haust Pipe.> TION, Muffler.>
 Turbo model
Exhaust Pipe.> STALLATION, Muffler.>
9) Lower the vehicle.
10) Install the plate assembly to body.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
11) Install the drive select cable. INSTALLATION, Drive Select Cable.>12) Install the boot and insulator assembly to the
vehicle in proper direction.
13) Install the clamp.
14) Install the console box. LATION, Console Box.>
C: DISASSEMBLY
1) Remove the lock wire.
2) Remove the rod from gear shift lever.
(A) Stay
(B) Transmission bracket
CS-00050
(A)
(B)
CS-00101
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00100
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)

CS-20
CONTROL SYSTEM
MT Gear Shift Lever
3) Remove the snap ring from bushing B, and then
disconnect the stay.
4) Remove the boot from gear shift lever.
5) Remove the bushing and cushion rubber from
stay.
6) Remove the O-ring, and then remove the bush-
ing B.7) Draw out the spring pin, and then remove the
bushing A from gear shift lever.
D: ASSEMBLY
1) Clean all parts before assembly.
2) Mount the bushing and cushion rubber on the
stay.
(A) Snap ring
(B) Bushing B
(C) Stay
(A) Bushing
(B) Stay
(C) Cushion rubber
(A) O-ring
(B) O-ring
(C) Bushing B
CS-00057
(A)(B)
(C)
CS-00058
(A)
(B)
(C)
CS-00059
(C)
(B)
(A)
(A) Spring pin
(B) Bushing A
(A) Bushing
(B) Cushion rubber
CS-00060
(B)
(A)
CS-00061
(A)
(B)

CS-21
CONTROL SYSTEM
MT Gear Shift Lever
3) Mount each part; boot, O-ring, bushing A, spac-
er, bushing B, bushing and spring pin on the gear
shift lever.
NOTE:
 Always use new O-rings.
 Apply grease [SUNLIGHT 2 (Part No. 003602010)
or equivalent] to the inner and side surfaces of the
bush when installing the spacer.
4) Insert the gear shift lever into boot hole.
5) Install the snap ring and stay to bushing B.6) Tighten with a lock wire to the extent that the
boot will not come off.
NOTE:
Always use new lock wire.
7) Insert the rod into boot hole.
8) Connect the rod to gear shift lever.
Tightening torque:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
(A) Boot
(B) O-ring
(C) Bushing
(D) Spacer
(E) Bushing A
(F) Bushing B
(G) Spring pin
(H) O-ring
(A) Snap ring
(B) Bushing B
CS-00062
(F)(D)(C)
(E)
(G)
(H)
(B)
(A)
CS-00165
(A)(B)
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)

CS-22
CONTROL SYSTEM
MT Gear Shift Lever
E: INSPECTION
1) Check each part (bushing, cushion rubber, spacer,
boot, stay, rod, etc.) for deformation, damage and
wear. Repair or replace any defective part. Determine
defective parts by comparing with new parts.
2) Check the swing torque of the rod connected to
gear shift lever.
If the torque exceeds specification, replace the
bushing or retighten nuts.
Swing torque:
3.7 N (0.38 kgf, 0.83 lb) or less3) Check that there is no excessive play and that
parts move smoothly.
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
(A) Center of rotation
(B) Swing torque
(C)
(D)(A) (F) (A)
CS-00064
(E)(B)
CS-00065
(A)
(B)

5MT-35
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
27) Using the ST, remove the front drive shaft from
side of transmission case.
NOTE:
 Face the “MT” letter stamped on handle of ST to
transmission.
 Contact the portion of ST to transmission case.
ST 28399SA000 FRONT DRIVE SHAFT RE-
MOVER
28) While holding the joint portion (AARi) of front
drive shaft with your hand, push the housing out-
side to remove from transmission without stretch-
ing AARi side of boot.
29) Remove the nuts which hold lower side of
transmission to engine.30) Place the transmission jack under transmis-
sion.
CAUTION:
Always support the transmission case with a
transmission jack.
31) Remove the transmission rear crossmember
from vehicle.
32) Remove the transmission.
NOTE:
Move the transmission jack toward rear until main
shaft is withdrawn from clutch cover.
33) Separate the transmission assembly and rear
cushion rubber.
(A) “MT” letter stamped
AT-00461
(A)
MT-00080ST
MT-00077
MT-00078
MT-00079

CL-9
CLUTCH SYSTEM
General Description
4. MASTER CYLINDER
 NON-TURBO MODEL
(1) Reservoir cap (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return springT1: 10 (1.0, 7)
(3) Oil seal (9) PistonT2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-00005
(1)
(2)
(3)
(4)
(5)
(7)
(6)
T2
T1
(8)
(9)(10) (11)
(12)

CL-10
CLUTCH SYSTEM
General Description
 LHD TURBO MODEL
(1) Reservoir cap (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return springT1: 10 (1.0, 7)
(3) Oil seal (9) PistonT2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-00109
(3)(1)
(4)
(5)
T1
(8)
(9)(11)(12)
(10)
(2)
(7)
(6)
T2

CL-11
CLUTCH SYSTEM
General Description
 RHD TURBO MODEL
(1) Reservoir cap (8) Oil sealTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (9) Master cylinderT1: 8 (0.8, 5.8)
(3) Washer (10) Return springT2: 10 (1.0, 7)
(4) Straight pin (11) PistonT3: 18 (1.8, 13.0)
(5) Clip (12) Push rod
(6) Hose (13) Piston stop ring
(7) Reservoir tank bracket (14) Cylinder boot
)
CL-00162
(8) (1)
(2)
(9)
T2
(10)
(11)(13)
(12) (14)
T1
T3
T3
(7)
(5)
(3) (3)
(6)
(5)
(4)

CL-25
CLUTCH SYSTEM
Operating Cylinder
B: INSTALLATION
1) Apply grease (SUNLIGHT 2: Part No.
003602010) to the contact point of the release lever
and operating cylinder.
2) Install in the reverse order of removal.
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: Part No. 003602010) to con-
tact point of the release lever and operating cylin-
der.
Tightening torque:
T1: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
T2: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
 NON-TURBO model
 TURBO modelNOTE:
 Be sure to install the clutch hose with the mark
side facing upward.
 Be careful not to twist the clutch hose during in-
stallation.
3) After bleeding air from the operating cylinder,
ensure that clutch operates properly.

C: INSPECTION
1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on boot. If any leakage or damage is
found, replace the operating cylinder.
T2
CL-00039T2
T1
CL-00040
T2
T1
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-00041
(A)
(B) (C)