height SUBARU FORESTER 2004 Service Owner's Guide

4AT-127
AUTOMATIC TRANSMISSION
AT Main Case
NOTE:
If three points, measure the height every 120°. If
four points, measure the height every 90°.
14) Installation of the low & reverse brake:
Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
NOTE:
Pay attention to the orientation of dish plate.15) Apply compressed air intermittently to check for
operation.
16) Measure the clearance.
Place the same thickness of shim on both sides to
prevent pressure plate from tilting, and then mea-
sure the clearance B and note it.
(A) Dish plate
(B) Driven plate
(C) Drive plate
(D) Retaining plate
(A) Snap ring
AT-01721
(B)
(D)
(C)
(A)
A
AT-00294
(A)
AT-00297
AT-01722
B

5MT-27
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398527700 PULLER ASSY  Used for removing extension case roller bear-
ing.
 Used for removing front differential side
retainer bearing outer race.
 Used for removing front differential side
retainer oil seal.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
398177700 INSTALLER  Used for installing bearing cone of transfer
driven gear (transfer case side).
 Used for installing ball bearing of transfer drive
gear.
398507703 DUMMY COLLAR  Used for installing input shaft holder oil seal.
 For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398527700
ST-398643600
ST-398177700
ST-398507703

5MT-50
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
11.Transfer Case and Extension
Case Assembly
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.
4) Remove the shifter arm.
5) Remove the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.2) Remove the bearing outer race from extension
case.
3) While pressing the bearing outer race horizontal-
ly, turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
5) Measure the depth “X”.
NOTE:
Measure with bearing cone and thrust washer re-
moved.
6) Calculate the space “t” using the following equa-
tion: t = X−W+0.2 to 0.3 mm (0.008 to 0.012 in)
7) Select the nearest washer in the following table:
Standard clearance between thrust washer and
taper roller bearing:
0.2 — 0.3 mm (0.008 — 0.012 in)
NOTE:
Set the clearance within standard clearance.
MT-00116
MT-00117
MT-00118
(A) Bearing outer race
(B) Extension case
MT-00119
(B)
(A)
MT-00120
W
MT-00121
X

5MT-102
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
 Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to bring drive pinion
close to crown gear.
 Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting shim in order to move drive pin-
ion away from crown gear. Toe contact (Inside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting shim in order to bring drive pin-
ion close to crown gear.
 Heel contact (Outside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to move drive pinion
away from crown gear.
AT-00208
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212