lock SUBARU FORESTER 2004 Service Repair Manual

5MT-19
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498247001 MAGNET BASE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with DIAL GAUGE (498247100).
498247100 DIAL GAUGE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with MAGNET BASE (498247001).
498427400 STOPPER Used for securing the drive pinion shaft assem-
bly and driven gear assembly when removing the
drive pinion shaft assembly lock nut.
498787100 MAIN SHAFT
STOPPERUsed for removing and installing transmission
main shaft lock nut. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498247001
ST-498247100
ST-498247400
ST-498787100

5MT-20
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498937000 TRANSMISSION
HOLDERUsed for removing and installing transmission
main shaft lock nut.
499277100 BUSH 1-2
INSTALLER Used for installing 1st driven gear thrust plate
and 1st-2nd driven gear bush.
 Used for installing roller bearing outer races to
differential case.
499277200 INSTALLER Used for press-fitting the 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.
499757002 INSTALLER  Used for installing snap ring (OUT 25), and
ball bearing (25×26×17).
 Used for installing bearing cone of transfer
driven gear (extension core side). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498937000
ST-499277100
ST-499277200
ST-499757002

5MT-22
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499917500 DRIVE PINION
GAUGE ASSYUsed for adjusting drive pinion shim.
499927100 HANDLE Used for fitting transmission main shaft.
499937100 TRANSMISSION
STAND SETStand used for transmission disassembly and
assembly.
499987003 SOCKET WRENCH
(35)Used for removing and installing driven pinion
lock nut and main shaft lock nut. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499917500
ST-499927100
ST-499937100
ST-499987003

5MT-23
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499987300 SOCKET WRENCH
(50)Used for removing and installing driven gear
assembly lock nut.
899714110 REMOVER Used for fixing transmission main shaft, drive
pinion, rear drive shaft.
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
899884100 HOLDER Used for tightening lock nut on sleeve. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499987300
ST-899714110
ST-899864100
ST-899884100

5MT-24
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899904100 REMOVER Used for removing and installing straight pin.
899988608 SOCKET WRENCH
(27)Used for removing and installing drive pinion lock
nut.
398497701 ADAPTER  Used for installing roller bearing onto differen-
tial case.
 Used with INSTALLER (499277100).
499587000 INSTALLER Used for installing driven gears to driven shaft. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899904100
ST-899988608
ST-398497701
ST-499587000

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-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-65
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
8) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing:
NOTE:
Support the drive pinion assembly with ST.
ST 498427100 STOPPER
9) Place the transmission with case left side facing
downward and put ST1 on bearing outer race.
10) Screw the retainer assembly into left case from
the bottom with ST2 Fit the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE11) Remove the weight and screw in the retainer
without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
12) Fit the lock plate. Loosen the retainer on the
lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
13) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. TION, Front Differential Assembly.>
MT-00174ST
MT-00175
ST3ST2
ST1
MT-00176
ST

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-67
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
8) Tighten the input shaft holder attaching bolts.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
9) Using the ST, support the drive pinion assembly,
and then adjust the backlash of hypoid gear and
measure preload of roller bearing.
ST 498427100 STOPPER
10) Place the transmission with case left side fac-
ing downward and put ST1 on bearing cup.11) Screw the retainer assembly into left case from
the bottom with ST2. Fit the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
12) Remove the weight and screw in the retainer
without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
13) Fit the lock plate. Loosen the retainer on the
lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
14) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
15) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
(A) Input shaft holder
(B) Input shaft
MT-00163
(A)
(B)
MT-00174ST
MT-00175
ST3ST2
ST1
MT-00176
ST