torque SUBARU FORESTER 2004 Service Repair Manual

5MT-48
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Pump
10.Oil Pump
A: REMOVAL
For extension case removal procedure, refer to
“Transfer Case and Extension Case Assembly”.
Extension Case Assembly.>
B: INSTALLATION
For extension case installation procedure, refer to
“Transfer Case Pump and Extension Case Assem-
bly”. Case and Extension Case Assembly.>
C: DISASSEMBLY
1) Remove the transfer drive gear assembly. to 5MT-54, REMOVAL, Transfer Drive Gear.>
2) Remove the oil strainer from extension case.
3) Remove the shift bracket.
4) Remove the relief valve from extension case.5) Remove the oil pump cover from extension.
6) Remove the rotor assembly, oil pump shaft and
O-ring.
D: ASSEMBLY
1) Install the rotor assembly and oil pomp shaft to
extension case.
2) Install a new O-ring to oil pump cover.
NOTE:
Apply a coat of gear oil to the O-ring.
3) Install the oil pump cover to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-00370
MT-00371
MT-00372
(A) Oil pump cover
(A) Oil pump shaft
(B) Rotor ASSY
(C) O-ring
(A) Oil pump cover
MT-00373
MT-00374
MT-00373

5MT-49
MANUAL TRANSMISSION AND DIFFERENTIAL
Oil Pump
4) Install a new O-ring, relief valve and return
spring to extension case.
Tightening torque:
12.75 N·m (1.3 kgf-m, 9.4 ft-lb)
5) Install the shift bracket to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
6) Install the oil strainer to extension case.
Tightening torque:
26 N·m (2.7 kgf-m, 19 ft-lb)
7) Install the transfer drive gear. INSTALLATION, Transfer Drive Gear.>E: INSPECTION
Use a thickness gauge to measure the chip clear-
ance of the rotor assembly. If the value exceeds
standard, replace the rotor as an assembly.
Chip clearance:
Less than 0.15 mm (0.0059 in)
MT-00375
MT-00371
MT-00370
MT-00376

5MT-51
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
8) Fit the thrust washers on transfer drive shaft.
9) Install the bearing outer race into extension
case.
10) Measure the depth “S” between transfer case
and center differential.
ST 398643600 GAUGE
11) Measure the depth “T” between extension case
and transfer drive gear.
ST 398643600 GAUGE12) Calculate the space “U” using the following
equation: U = S+T−30 mm (1.18 in) [Thickness of
ST]
13) Select the suitable washer in the following ta-
ble:
Standard clearance:
0.15 — 0.35 mm (0.0059 — 0.0138 in)
14) Fit the thrust washer on center differential.
15) Apply proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. : 004403007)
16) Install the extension assembly into transfer
case.
Tightening torque:
40 N·m (4.1 kgf-m, 30 ft-lb)
Thrust washer (50×61×t)
Part No. Thickness mm (in)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
MT-00122
ST
S
MT-00123
T
ST
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
MT-00124
MT-00117

5MT-52
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
17) Install the shifter arm to transfer case.
18) Hang the shifter arm on 3rd-4th fork rod.
19) Install the transfer case with extension case as-
sembly to transmission case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. 5MT-59, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. to 5MT-54, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
3) Remove the oil seal from extension case. to 5MT-41, REPLACEMENT, Oil Seal.>
(A) Shifter arm
(B) 3rd-4th fork rod
MT-00126
MT-00127
(A)
(B)
MT-00116
MT-00129
MT-00130

5MT-53
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, insert the new oil seal to extension
case. Seal.>
2) Install the shift bracket to extension case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Install the transfer drive gear to extension case.
Gear.>
2. TRANSFER CASE
1) Install the oil guide to transfer case.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
2) Install the reverse check sleeve assembly to
transfer case. Reverse Check Sleeve.>
MT-00130
MT-00129

5MT-54
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
12.Transfer Drive Gear
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. Case and 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. fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>6) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
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. Drive Gear.>
MT-00133
MT-00133
MT-00135
MT-00136
MT-00137
ST

5MT-59
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Check Sleeve
15.Reverse Check Sleeve
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring
and reverse check ball.
5) Remove the reverse check sleeve.
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
2) Install the reverse check ball, reverse accent
spring, gasket and plug to transfer case.
Tightening torque:
9.75 N·m (1.0 kgf-m, 7.2 ft-lb)
3) Install the shifter arm to transfer case assembly.
4) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
MT-00149
MT-00150
MT-00150
MT-00149

5MT-64
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
11) Remove the main shaft assembly and input
shaft assembly.
NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.
12) Remove the differential assembly.
NOTE:
 Be careful not to confuse the right and left roller
bearing outer races.
 Be careful not to damage the retainer oil seal.
B: INSTALLATION
1. SINGLE-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.
Install the needle bearing knock pin hole into trans-
mission 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 (Part No. : 004403007) or
equivalent6) Tighten the seven teen 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 drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
 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 (0.39 in) 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)
(A) Main shaft ASSY
(B) Input shaft ASSY
MT-00170
(A)
(B)
MT-00162
(9)(7)
(5)
(1)
(2)(16)
(17)
(11)
(3)
(4)
(12)
(8) (6) (10) (14) (15)(13)
MT-00172
MT-00158

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