light SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2754 of 2870
5MT-42
MANUAL TRANSMISSION AND DIFFERENTIAL
Differential Side Retainer Oil Seal
6. Differential Side Retainer Oil
Seal
A: INSPECTION
Check the differential side retainer oil seal for leak-
age of gear oil. If oil leaks, replace the oil seal.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Drain the gear oil from oil drain plug.
3) Replace the gasket with new one, and then tight-
en the differential oil drain plug.
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 front exhaust pipe and center ex-
haust pipe. (Non-turbo model)
5) Separate the front drive shaft from transmission.
6) Using a vinyl tape, etc. wrapped flat tip screw-
driver, remove the differential side retainer oil seal.7) Using the ST, install the differential side retainer
oil seal tapping ST lightly with a hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
Be sure to apply oil to oil seal lip surface.
8) Install the front drive shaft.
9) Install the front exhaust pipe and center exhaust
pipe. (Non-turbo model)
10) Lower the vehicle.
11) Fill gear oil into the gauge hole.
(A) Drain plug
(A) Drain plug
(A)
MT-00339
(A)
MT-00339
MT-00103
ST
Page 2755 of 2870
5MT-43
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
7. Switches and Harness
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.
3) Remove the intercooler (Turbo model).
4) Disconnect the connector of back-up light switch
and neutral position switch.
Non-turbo model
Turbo model
5) Lift-up the vehicle.6) Remove the back-up light switch and neutral po-
sition switch with harness.
2. HIGH-LOW SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.
3) Disconnect the connector of high-low switch.
4) Remove the high-low switch cable from clamp.
5) Remove the high-low switch.
(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
MT-00107
(B)
(C)
(A)
MT-00105
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
(A) Clamp
(B) High-low switch
MT-00106
(A)
(B)
MT-00107
(B)
(C)
(A)
MT-00108
(B)(A)
Page 2756 of 2870
5MT-44
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
B: INSTALLATION
1. BACK-UP LIGHT SWITCH AND NEU-
TRAL POSITION SWITCH
1) Install the back-up light switch and neutral posi-
tion switch with harness.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Connect the connector of back-up light switch
and neutral position switch.
3) Install the air intake duct and cleaner case.
4) Install the intercooler. (Turbo model)
5) Connect the battery ground cable to battery.
2. HIGH-LOW SWITCH
1) Install the high-low switch.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Install the high-low switch cable to clamp.
3) Connect the connector of high-low switch.
4) Install the air intake duct and cleaner case.
5) Connect the battery ground cable to battery.
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
MT-00106
(A)
(B)
Page 2757 of 2870
5MT-45
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch.
2. NEUTRAL POSITION SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model:
Turbo model:
Non-turbo model
Turbo model
4) Replace defective parts.
3. HIGH-LOW SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
4) Replace the defective parts.
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3Less than 1 Ω
Other positions More than 1 MΩ
MT-00110
1 2
MT-00111
1 2
3 4
Gear shift position Terminal No. Specified resistance
LO position
1 and 2Less than 1 Ω
HIGH position More than 1 MΩ
MT-00112
1 2
Page 2762 of 2870
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.
2) Remove the back-up light switch and neutral po-
sition switch.
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
Page 2766 of 2870
5MT-54
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
12.Transfer Drive Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle.
2) Remove the back-up light switch and neutral po-
sition switch.
3) Remove the transfer case with extension case
assembly.
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
26 N·m (2.7 kgf-m, 20 ft-lb)
2) Install the transfer driven gear.
3) Install the extension case assembly.
4) Install the transfer case and extension case as-
sembly.
5) Install the back-up light switch and neutral posi-
tion switch.
hicle.
C: DISASSEMBLY
1) Remove the snap ring.
2) Remove the ball bearing.
D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
install to drive shaft.
ST 398177700 INSTALLER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
2) Install the snap ring on transfer drive shaft.
3) Check the clearance between snap ring and ball
bearing.
MT-00133
MT-00133
MT-00135
MT-00136
MT-00137
ST
Page 2769 of 2870
5MT-56
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Driven Gear
13.Transfer Driven Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle.
2) Remove the back-up light switch and neutral po-
sition switch.
3) Remove the transfer case with extension case
assembly.
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the bearing outer race from extension
case and transfer case.
B: INSTALLATION
1) Install the bearing outer race to extension case
and transfer case.
2) Install the transfer driven gear.
3) Install the transfer case and extension case as-
sembly.
4) Install the back-up light switch and neutral posi-
tion switch.
5) Install the manual transmission assembly to ve-
hicle.
(A) Bearing outer race (transfer case)
(B) Bearing outer race (extension case)
MT-00118
MT-00140 (B)
(A)
(A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension case
(C)
(A)
(D)(B)
MT-00141
MT-00118
Page 2771 of 2870
5MT-58
MANUAL TRANSMISSION AND DIFFERENTIAL
Center Differential
14.Center Differential
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle.
2) Remove the transfer case with extension case
assembly.
3) Remove the extension case assembly.
Case Assembly.>
4) Remove the transfer driven gear.
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear.
3) Install the extension case assembly.
tension Case Assembly.>
4) Install the transfer case with extension case as-
sembly.
5) Install the back-up light switch and neutral posi-
tion switch.
6) Install the manual transmission assembly to ve-
hicle.
C: DISASSEMBLY
1) Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
2) Do not disassemble the center differential ex-
cept ball bearing part because it is a non-disassem-
ble part.
D: ASSEMBLY
Install the ball bearing to center differential assem-
bly.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
Bearings having other defects
2) Center differential
Replace the center differential assembly in the fol-
lowing case:
Worn or damaged
MT-00147
ST
(A) Ball bearing
MT-00148 (A)
Page 2774 of 2870
5MT-61
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Check Sleeve
E: INSPECTION
Make sure the cutout section of reverse accent
shaft is aligned with the opening in reverse check
sleeve.
Spin the cam by hand for smooth rotation.
Move the cam and shaft all the way toward plate
and release.
If the cam does not return properly, replace the re-
verse check spring; if shaft does not, check for
scratches on the inner surface of sleeve. If sleeve
is in good order, replace the spring.
Select a suitable reverse accent shaft and re-
verse check plate.
F: ADJUSTMENT
1. NEUTRAL POSITION ADJUSTMENT
1) Shift the gear into 3rd gear position.
2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side be-
cause of the function of return spring, until arm con-
tacts the stopper.
3) Make adjustment so that the heavy stroke (re-
verse side) is a little more than the light stroke (1st/
2nd side).
4) To adjust, remove the bolts holding reverse
check sleeve assembly to the case, move the
sleeve assembly outward, and place adjusting
shim (0 to 1 ea.) between sleeve assembly and
case to adjust the clearance.5) Be careful not to break the O-ring when placing
shim(s).
NOTE:
When the shim is removed, the neutral position
will move closer to reverse; when shim is added,
the neutral position will move closer to 1st gear.
If the shims alone cannot adjust clearance, re-
place the reverse accent shaft and re-adjust.
2. REVERSE CHECK PLATE ADJUST-
MENT
1) Shift the shifter arm to “5th” and then to reverse
to see if reverse check mechanism operates prop-
erly.
2) Also check to see if the arm returns to neutral
when released from reverse position. If the arm
does not return properly, replace the reverse check
plate.
(A) Snap ring
(B) Reverse check plate
(C) Check spring
(D) Check cam
MT-00156
(A) (D)
(B)(C)
Adjusting shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA130 SNeutral position is closer to 1st
gear.
32188AA140 T Standard
32188AA150 UNeutral position is closer to
reverse gear.
Reverse check plate
Par t No.(A):
No.Angle
θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
32189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
MT-00157(A)
Page 2778 of 2870
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.
MT-00174ST
MT-00175
ST3ST2
ST1
MT-00176
ST