meter SUBARU FORESTER 2004 Service Repair Manual

MANUAL TRANSMISSION AND
DIFFERENTIAL
5MT
Page
1. General Description ....................................................................................2
2. Transmission Gear Oil ..............................................................................31
3. Manual Transmission Assembly ...............................................................32
4. Transmission Mounting System ................................................................39
5. Oil Seal......................................................................................................41
6. Differential Side Retainer Oil Seal.............................................................42
7. Switches and Harness ..............................................................................43
8. Vehicle Speed Sensor...............................................................................46
9. Preparation for Overhaul ...........................................................................47
10. Oil Pump ...................................................................................................48
11. Transfer Case and Extension Case Assembly..........................................50
12. Transfer Drive Gear ..................................................................................54
13. Transfer Driven Gear ................................................................................56
14. Center Differential .....................................................................................58
15. Reverse Check Sleeve..............................................................................59
16. Transmission Case ...................................................................................62
17. Main Shaft Assembly For Single-Range ...................................................69
18. Main Shaft Assembly For Dual-Range ......................................................77
19. Input Shaft Assembly ................................................................................83
20. Drive Pinion Shaft Assembly .....................................................................87
21. Front Differential Assembly .......................................................................96
22. Speedometer Gear..................................................................................103
23. Reverse Idler Gear ..................................................................................104
24. Shifter Fork and Rod ...............................................................................106
25. Counter Gear ..........................................................................................109
26. General Diagnostic..................................................................................111

5MT-7
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
 Transmission case tightening torque
(1) Transmission case ASSY (Single-
range)(9) Oil seal (16) High-low cable bracket A (Dual-
range)
(10) Clamp
(2) Gasket (11) Pitching stopper bracket (17) High-low cable bracket B (Dual-
range)
(3) Drain plug (12) Clip
(4) Snap ring (Outer) (13) Oil level gauge (Non-turbo model) (18) Oil level gauge (Turbo model)
(5) Speedometer driven gear (14) Oil seal (Dual-range)
(6) Washer (15) Transmission case ASSY (Dual-
range)Tightening torque: N·m (kgf-m, ft-lb)
(7) Speedometer shaftT: 44 (4.5, 32.5) (Aluminum gasket)
(8) Snap ring (Outer)70 (7.1, 51.6) (Copper gasket)
Bolt No. Bolt sizeTightening torque:
N·m (kgf-m, ft-lb)
<5> to <15> 8 mm 25 (2.5, 18.1)
<1> to <4>
<16>, <17> 10 mm 39 (4.0, 28.9)
MT-00003

5MT-21
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
499827000 PRESS Used for installing speedometer oil seal when
installing speedometer cable to transmission.
499857000 5TH DRIVEN GEAR
REMOVERUsed for removing 5th driven gear.
499877000 RACE 4-5
INSTALLER Used for installing 4th needle bearing race and
ball bearing onto transmission main shaft.
 Used with REMOVER (899714110). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499787000
ST-499827000
ST-499857000
ST-499877000

5MT-25
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899824100 PRESS Used for installing speedometer shaft oil seal.
499987100 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
899984103 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
498057300 INSTALLER Used for installing extension oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899824100
ST-499987100
ST-899984103
ST-498057300

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-64
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
11) Remove the main shaft assembly and input
shaft assembly.
NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.
12) Remove the differential assembly.
NOTE:
 Be careful not to confuse the right and left roller
bearing outer races.
 Be careful not to damage the retainer oil seal.
B: INSTALLATION
1. SINGLE-RANGE
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the needle bearing knock pin hole into trans-
mission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
THREE BOND 1215 (Part No. : 004403007) or
equivalent6) Tighten the seven teen bolts with bracket, clip,
etc. as shown in the figure.
NOTE:
 Insert the bolts from bottom and tighten the nuts
at top.
 Put the cases together so that drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
 Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm (0.39 in) bolt
39 N·m (4.0 kgf-m, 28.9 ft-lb)
7) Tighten the bearing attachment bolts.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
(A) Main shaft ASSY
(B) Input shaft ASSY
MT-00170
(A)
(B)
MT-00162
(9)(7)
(5)
(1)
(2)(16)
(17)
(11)
(3)
(4)
(12)
(8) (6) (10) (14) (15)(13)
MT-00172
MT-00158

5MT-66
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
17) 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: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
18) Selecting of main shaft rear plate. 5MT-76, ADJUSTMENT, Main Shaft Assembly For
Single-Range.>
19) Install the clutch release lever and bearing.
and Lever.>
20) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
21) Install the manual transmission assembly into
the vehicle. Manual Transmission Assembly.>
2. DUAL-RANGE
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly and input shaft
assembly.
Connect the main shaft assembly and input the
shaft assembly, and install needle bearing knock
pin hole into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
THREE BOND 1215 (Parts No. 004403007) or
equivalent6) Tighten the seventeen bolts with bracket, clip,
etc. as shown in the figure.
NOTE:
 Insert the bolts from bottom and tighten the nuts
at top.
 Put the cases together so that the drive pinion
shim and input shaft holder shim are not caught up
in between.
 Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm bolt
39 N·m (4.0 kgf-m, 28.9 ft-lb)
7) Tighten the bearing attachment bolts.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
MT-00177
T
MT-00178
(9)
(7) (5)(16)
(17)
(11)
(3)
(4) (2) (1)
(12) (8) (6) (10) (14) (15) (13)
MT-00158

5MT-103
MANUAL TRANSMISSION AND DIFFERENTIAL
Speedometer Gear
22.Speedometer Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. es and Harness.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
4) Remove the transmission case. 62, REMOVAL, Transmission Case.>
5) Remove the vehicle speed sensor. 5MT-46, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out speed-
ometer driven gear. Next, remove the oil seal,
speedometer shaft and washer.
B: INSTALLATION
1) Install the washer and speedometer shaft, and
press fit the new oil seal with ST.
ST 899824100 or 499827000PRESS
2) Install the vehicle speed sensor. 46, INSTALLATION, Vehicle Speed Sensor.>
3) Install the speedometer driven gear and new
snap ring.
4) Install the transmission case. INSTALLATION, Transmission Case.>
5) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
6) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
7) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
(A) Outer snap ring
(B) Speedometer driven gear
MT-00301
(A)(B)
(A) Outer snap ring
(B) Speedometer driven gear
MT-00301
(A)(B)

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)