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 2780 of 2870
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
Page 2781 of 2870
5MT-68
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
16) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
17) Inspect and adjust the backlash and tooth con-
tact of hypoid gear.
18) 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: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
19) Selection of main shaft rear plate
gle-Range.>
20) Install the transfer case with extension case as-
sembly.
21) Install the clutch release lever and bearing.
22) Install the manual transmission assembly into
the vehicle.
Check the transmission case for cracks, damage,
and oil leaks.
MT-00177
T
Page 2789 of 2870
5MT-76
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are dam-
aged.
When the ring inner surface is abnormally or par-
tially worn down.
When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
F: ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bear-
ing protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
ST 498147000 DEPTH GAUGE
MT-00208
Dimension (A)
mm (in)Par t No. Mar k
4.00 — 4.13
(0.1575 —
0.1626)32294AA041 1
3.87 — 3.99
(0.1524 —
0.1571)32294AA051 2
MT-00209
(A)
Page 2798 of 2870
5MT-85
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
6) Drive the oil seal into input shaft holder.
NOTE:
Apply a coat of grease to sealing lips before install-
ing oil seal.
ST 398507703 DUMMY COLLAR
7) Wind vinyl tape around the shaft splines and in-
sert input shaft into holder by lightly tapping it by
hand.8) Install the snap ring to input shaft holder.
NOTE:
Select a suitable snap ring so that clearance be-
tween snap ring and bearing is held within 0 to 0.12
mm (0 to 0.0047 in).
ST 398663600 PLIERS
9) Install the O-ring to input shaft holder.
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
(A) Vinyl tape
(B) Input shaft
MT-00235
ST
MT-00236
(A)(B)
Snap ring
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
(A) O-ring
(B) Input shaft holder
MT-00227
ST
MT-00238
(A)
(B)
Page 2806 of 2870
5MT-93
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
The roller bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are dam-
aged.
When the ring inner surface is abnormally or par-
tially worn down.
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 — 1.0 mm (0.020 — 0.040 in)
When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
(A) Drive pinion shaft
(B) Roller bearing
MT-00264
(A)
(B)
MT-00265
(A)
MT-00208
Page 2814 of 2870
5MT-101
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
3. TOOTH CONTACT OF HYPOID GEAR
Check the tooth contact of hypoid gear as follows:
Apply a uniform thin coat of red lead on both tooth
surfaces of 3 or 4 teeth of the hypoid gear. Move
the hypoid gear back and forth by turning the trans-
mission main shaft until a definite contact pattern is
developed on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment.
Tooth contact is correct.
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential.
2) Select a different washer from the table and in-
stall.
3) Adjust until the specified value is obtained.
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
Adjust backlash by turning the holder in right side
case.
ST 499787000 WRENCH ASSY
NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.0020 in).
3. TOOTH CONTACT OF HYPOID GEAR
1) Adjust until the teeth contact is correct.
2) Check and adjust the teeth contact with following
table.
Tooth contact
Checking item:Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
Washer
Part No. Thickness mm (in)
8030380210.925 — 0.950
(0.0364 — 0.0374)
8030380220.975 — 1.000
(0.0384 — 0.0394)
803038023 1.025 — 1.050
(0.0404 — 0.0413)
MT-00294
(A)
(B) (C)
(D)
(A) Toe side
(B) Heel side
MT-00176
ST
MT-00296
0.05mm(0.0020 in)
AT-00207
(A)
(B)
Page 2816 of 2870
5MT-103
MANUAL TRANSMISSION AND DIFFERENTIAL
Speedometer Gear
22.Speedometer 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 transmission case.
5) Remove the 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.
3) Install the speedometer driven gear and new
snap ring.
4) Install the transmission case.
5) Install the transfer case with extension case as-
sembly.
6) Install the back-up light switch and neutral posi-
tion switch.
7) Install the manual transmission assembly to ve-
hicle.
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)
Page 2817 of 2870
5MT-104
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
23.Reverse Idler 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 transmission case.
5) Remove the drive pinion shaft assembly.
bly.>
6) Remove the main shaft assembly.
Single-Range model
Dual-Range model
7) Remove the differential assembly.
8) Remove the shifter forks and rods.
9) Pull out the straight pin, and remove the Rev
idler gear shaft, reverse idler gear and washer.
10) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse shifter lever, reverse idler
gear and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall.
and
3) Install the shifter forks and rods.
4) Install the differential assembly.
5) Install the main shaft assembly.
Single-Range model
Dual-Range model
6) Install the drive pinion shaft assembly.
sembly.>
7) Install the transmission case.
8) Install the transfer case with extension case as-
sembly.
9) Install the back-up light switch and neutral posi-
tion switch.
10) Install the manual transmission assembly to ve-
hicle.
(A) Straight pin
(B) Rev idler gear shaft
(C) Rev idler gear
(D) Washer
MT-00303
(A)(B)
(C)
(D)
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
MT-00304
(A)
(B)
(D)
(C)
Page 2819 of 2870
5MT-106
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
24.Shifter Fork and Rod
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 transmission case.
5) Remove the drive pinion shaft assembly.
bly.>
6) Remove the main shaft assembly.
Single-Range model
Dual-Range model
7) Remove the differential assembly.
8) Drive out the straight pin with ST, and 5th shifter
fork.
ST 398791700 STRAIGHT PIN REMOVER
9) Remove the plugs, springs and checking balls.10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
NOTE:
When removing the rod, keep other rods in neutral.
11) Drive out the straight pin, and pull out 1st-2nd
fork rod and shifter fork.
12) Remove the outer snap ring, and pull out the
reverse shifter rod arm from reverse fork rod. Then
take out the ball, spring and interlock plunger from
rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be
careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
B: INSTALLATION
1) Apply grease to plunger.
ST 399411700 ACCENT BALL INSTALLER
2) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into hole in reverse fork rod arm, and
hold it with outer snap ring using ST.
3) Position the ball, spring and new gasket in re-
verse shifter rod hole, on left side transmission
case, and tighten the checking ball plug.
4) Install the 1st-2nd fork rod into 1st-2nd shifter
fork via the hole on the rear of transmission case.
5) Align the holes in rod and fork, and new drive
straight pin into these holes using ST.
NOTE:
Set other rods to neutral.
Make sure the interlock plunger is on the 3rd-4th
fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
6) Apply a coat of grease to plunger.
7) Install the interlock plunger onto 3rd-4th fork rod.
8) Install the 3rd-4th fork rod into 3rd-4th shifter fork
via the hole on the rear of transmission case.
(A) Straight pin
(B) 5th shifter fork
MT-00309(A) (B)
(A) Straight pin
(B) 3rd-4th fork rod
(C) Shifter fork
MT-00310(A)
(B) (C)
Page 2820 of 2870
5MT-107
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
9) Align the holes in rod and fork, and new drive
straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make sure the interlock plunger (installing be-
fore) is on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
10) Install the 5th shifter fork onto the rear of re-
verse fork rod. Align holes in the two parts and new
drive straight pin into place.
ST 398791700 STRAIGHT PIN REMOVER
11) Position the balls, checking ball springs and
new gaskets into 3rd-4th and 1st-2nd fork rod
holes, and install plugs.
12) Install the differential assembly.
13) Install the main shaft assembly.
Single-Range model
Dual-Range model
sembly.>
15) Install the transmission case.
16) Install the transfer case with extension case as-
sembly.
17) Install the back-up light switch and neutral po-
sition switch.
18) Install the manual transmission assembly to ve-
hicle.
C: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism:
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
MT-00311(C) (A) (B)
MT-00311(C) (A) (B)(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in).
32804AA070 — Standard
32804AA080 3Approach to 2nd gear
by 0.2 mm (0.008 in).
MT-00313
(A)
(B)
(C) (a)(b)