torque SUBARU FORESTER 2004 Service Repair Manual

5MT-36
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
B: INSTALLATION
1) Replace the differential side retainer oil seal with
a new one. ferential Side Retainer Oil Seal.>
NOTE:
When pulling out the front drive shaft, always re-
place the differential side retainer oil seal.
2) Install the rear cushion rubber to transmission
assembly.
Tightening torque:
35 N·m (3.57 kgf-m, 25.8 ft-lb)
3) Install the clutch release lever and bearing onto
transmission. (Turbo model) STALLATION, Release Bearing and Lever.>
4) Install the transmission onto engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
NOTE:
Be careful not to strike the main shaft against clutch
cover.
5) Install the transmission rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
6) Take off the transmission jack.
7) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)8) Connect the engine and transmission.
(1) Install the starter.
er.>
(2) Tighten the bolts which holds right upper
side of transmission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
9) Remove the ST.
10) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
11) Lift-up the vehicle.
12) Install the front drive shaft into transmission.
Shaft.>
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
MT-00081
T2T2
T1T1
MT-00077
MT-00073
MT-00070
ST
AT-00025
T1
T2

5MT-37
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
13) Install the ball joints of lower arm into knuckle
arm of housing, and tighten the installing bolts.
Tightening torque:
49 N·m (5.0 kgf-m, 36 ft-lb)
14) Install the stabilizer link from transverse link.
Tightening torque:
45 N·m (4.6 kgf-m, 33.2 ft-lb)15) Install the gear shift rod and stay.
(1) Install the gear shift rod onto transmission.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(2) Install the stay onto transmission.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
16) Install the propeller shaft. STALLATION, Propeller Shaft.>
17) Connect the cooler hose to oil pipe. (Model with
oil pump)
18) Install the heat shield cover. (If equipped mod-
el)
19) Install the hanger bracket on right side of trans-
mission.
20) Install the rear exhaust pipe and muffler.
21) Install the front exhaust pipe and center ex-
haust pipe. (Non-turbo model) 8, INSTALLATION, Front Exhaust Pipe.>
22) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
23) Install the under cover.
(A) Transverse link
(B) Ball joint
MT-00086
(A)
(B)
MT-00076
(A) Stay
(B) Gear shift rod
MT-00089
(A)
(B)
(B)
MT-00074

5MT-38
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
24) Push clutch release lever to fit bearing into
clutch cover.
25) Install the operating cylinder.
Tightening torque:
37 N·m (3.8 kgf-m, 27.5 ft-lb)
 Non-turbo model
 Turbo model26) Install the drive select cable on transmission.
(Dual-range model)
27) Connect the following connectors:
(1) Transmission ground cable
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
(5) High-low switch connector (Dual-range
model)
28) Install the air cleaner case stay.
29) Install the air cleaner case and duct. IN(H4SO)-6, INSTALLATION, Air Cleaner Case.>
Duct.>
30) Install the intercooler.(TURBO MODEL) to IN(H4DOTC)-11, INSTALLATION, Intercooler.>
31) Fill gear oil into the gauge hole.
Gear Oil.>
32) Connect the battery ground cable to battery.
33) Take off the vehicle from lift arms.
MT-00377
MT-00067
MT-00068
(A) Snap pin
(B) Clevis pin
(C) Drive select cable
MT-00066
(A)
(B)
(C)

5MT-39
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Mounting System
4. Transmission Mounting Sys-
tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.
3) Remove the air intake duct. (Non-turbo model)

4) Remove the air cleaner case. (Non-turbo model)
Case.>
5) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
6) Remove the pitching stopper.
2. CROSSMEMBER AND CUSHION RUB-
BER
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle and support it with rigid
racks.
3) Remove the front and center exhaust pipes.
(Non-turbo model)
Pipe.>
haust Pipe.>
4) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped mod-
el)
7) Set the transmission jack under the transmission
body.
CAUTION:
Always support the transmission case with a
transmission jack. 8) Remove the rear crossmember.
9) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
2) Install the air intake duct and cleaner case.
(Non-turbo model)
Case.> Intake Duct.>
3) Install the intercooler. (Turbo model) IN(H4DOTC)-11, INSTALLATION, Intercooler.>
4) Connect the battery ground cable to battery.
AT-00023
MT-00079
AT-00025
T1
T2

5MT-40
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Mounting System
2. CROSSMEMBER AND CUSHION RUB-
BER
1) Install the rear cushion rubber.
Tightening torque:
35 N·m (3.6 kgf-m, 26 ft-lb)
2) Install the rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
3) Remove the transmission jack.
4) Install the heat shield cover. (If equipped model)
5) Install the front and center exhaust pipes. (Non-
turbo model)
haust Pipe.>
6) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
7) Install the rear exhaust pipe and muffler.
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfactory.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Make sure that the rubber is not stiff,
cracked or otherwise damaged.
2. CROSSMEMBER AND CUSHION RUB-
BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked or otherwise damaged.
MT-00081
T2T2
T1T1

5MT-41
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Seal
5. Oil Seal
A: INSPECTION
Check the oil seal portion for leakage. If leakage is
found, replace the oil seal with a new one.
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the gear oil completely.
3) Replace the gasket with a new one, and then
tighten the drain plug after draining gear oil.
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 rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped mod-
el)
6) Remove the propeller shaft. MOVAL, Propeller Shaft.>
7) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY8) Using the ST, install the oil seal.
ST 498057300 INSTALLER
9) Install the propeller shaft. STALLATION, Propeller Shaft.>
10) Install the heat shield cover. (If equipped mod-
el)
11) Install the rear exhaust pipe and muffler.
12) Pour gear oil and check the oil level. 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
(A) Oil seal
MT-00097
MT-00098
(A)ST
MT-00099

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) 7, REMOVAL, Front Exhaust Pipe.>
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. STALLATION, Front Drive Shaft.>
9) Install the front exhaust pipe and center exhaust
pipe. (Non-turbo model) STALLATION, Front Exhaust Pipe.>
10) Lower the vehicle.
11) Fill gear oil into the gauge hole. 31, REPLACEMENT, Transmission Gear Oil.>
(A) Drain plug
(A) Drain plug
(A)
MT-00339
(A)
MT-00339
MT-00103
ST

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. to IN(H4SO)-7, INSTALLATION, Air Intake Duct.>
Case.>
4) Install the intercooler. (Turbo model)
cooler.>
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. to IN(H4SO)-7, INSTALLATION, Air Intake Duct.>
Case.>
5) Connect the battery ground cable to battery.
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
MT-00106
(A)
(B)

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-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