torque SUBARU FORESTER 2004 Service Repair Manual

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. TION, Front Differential Assembly.>
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 76, ADJUSTMENT, Main Shaft Assembly For Sin-
gle-Range.>
20) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
21) Install the clutch release lever and bearing.
and Lever.>
22) Install the manual transmission assembly into
the vehicle. Manual Transmission Assembly.>C: INSPECTION
Check the transmission case for cracks, damage,
and oil leaks.
MT-00177
T

5MT-73
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 2. TURBO MODEL
1) Assemble each sleeve and hub assembly.
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on transmission main
shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
(A) 5th needle bearing
(B) 5th drive gear
(C) 5th baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th-Rev hub ASSY
(D) 5th gear side
(A) 3rd needle bearing
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
MT-00191 (D) (C)(B) (A)
MT-00200
(A)
(B)
(C) (D)(E)
(F)

5MT-75
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
9) Make sure the synchro cone rotates smoothly af-
ter press-fitting.
ST 499757002 INSTALLER
10) Install the synchro cone stopper and snap ring
to 5th-Rev sleeve and hub assembly.11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
(B) (A)
(C)
ST
MT-00188
(A) (B)
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)

5MT-81
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Dual-Range
11) Install rest of the parts to the rear section of
transmission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
13) Install the needle bearing on main shaft.14) Install the rest of parts to the front section of
transmission main shaft.
NOTE:
 Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
 Face the grooved side toward input gear.
 Align the high-low baulk ring’s groove with shift-
ing insert.
15) Install a new snap ring to the rod section of
transmission main shaft using ST1 and ST2.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1 499757002 INSTALLER
ST2 499757001 SNAP RING GUIDE
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
(A) Ball
(B) Input low gear spacer
(C) Needle bearing
(D) Low input gear
(E) Friction damper
(F) High-low baulk ring
(G) Sleeve and hub ASSY
Snap ring
Part No. Thickness mm (in)
805025058 2.37 (0.0933)
805025051 2.42 (0.0953)
805025052 2.47 (0.0972)
805025053 2.52 (0.0992)
805025054 2.57 (0.1012)
805025055 2.62 (0.1031)
805025056 2.67 (0.1051)
805025057 2.72 (0.1071)
MT-00225
(F)
(G)(C)(B)(A)
(D)
(E)
(F)

5MT-91
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
6) After installing the key on driven shaft, install the
3rd-4th driven gear using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Align the convex part in baulk ring with insert.
ST 499277200 INSTALLER
7) Install a set of roller bearings onto the driven
shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER
8) Position the woodruff key in groove on the rear
of driven shaft. Install the 5th driven gear onto driv-
en shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER9) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
260 N·m (26.5 kgf-m, 192 ft-lb)
NOTE:
 Stake the lock nut at two points.
 Using the spring balancer, check that starting
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
kgf, 0.02 to 0.33 ft).
10) Install the roller bearing onto drive pinion.
NOTE:
When installing the roller bearing, note its direc-
tions (front and rear) because the knock pin hole in
outer race is offset.
MT-00255
ST
MT-00256
ST
MT-00257
ST
(A) Roller bearing
(B) Knock pin hole
MT-00258
ST
MT-00259
MT-00260
(A)
(B)

5MT-94
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select the adjusting washer No. 1 so that dimen-
sion (H) is zero through visual check. Position the
washer (18.3×30×4) and lock washer (18×30×2)
and install the lock nut (18×13.5).
2) Using the ST1, ST2 and ST3, tighten the lock nut
to specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 3) After removing the ST2, measure the starting
torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
lb)
4) If the starting torque is not within specified limit,
select a new adjusting washer No. 1 and recheck
starting torque.
MT-00267 (H)
MT-00268
ST1
ST2
ST3
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
MT-00269
ST1
ST3
MT-00270
(A)
(B)

5MT-95
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
5) If the specified starting torque range cannot be
obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
6) Recheck that the starting torque is within speci-
fied range, then clinch the lock nut at four positions.
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
MT-00270
(A)
(B)

5MT-99
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
4) Install the roller bearing to differential case.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
5) Install the hypoid driven gear to differential case
using twelve bolts.
Tightening torque:
T: 62 N·m (6.3 kgf-m, 45.6 ft-lb)2. SIDE RETAINER
1) Install a new oil seal.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
CAUTION:
 When pressing fit the oil seal to side retainer,
tap it to press fit using a plastic hammer.
 Do not use the press.
2) Install a new O-ring.
NOTE:
Do not stretch or damage the O-ring.
(A) Hypoid driven gear
(B) Differential case
MT-00287
ST1
ST2
MT-00288
(B) (A)T
MT-00289
ST
MT-00279

CL-3
CLUTCH SYSTEM
General Description
B: COMPONENT
1. CLUTCH ASSEMBLY
 NON-TURBO MODEL
(1) Clutch release lever dust cover (6) Clutch release bearingTightening torque: N⋅m (kgf-m, ft-lb)
(2) Retainer spring (7) Clutch coverT1: 16 (1.6, 11.6)
(3) Pivot (8) Clutch discT2: 72 (7.3, 52.8)
(4) Clutch release lever (9) Flywheel
(5) Clip
CL-00284
(4)
(2) (1)
(9)(5)
(6)
(7)
(8)(3)
(5)
T2
T1
T1

CL-4
CLUTCH SYSTEM
General Description
 TURBO MODEL
(1) Clutch release lever dust cover (5) Clutch release bearingTightening torque: N⋅m (kgf-m, ft-lb)
(2) Clutch release lever (6) Clutch coverT1: 16 (1.6, 11.6)
(3) Clutch release lever shaft (7) Clutch discT2: 44 (4.5, 32.5)
(4) Plug (8) FlywheelT3: 72 (7.3, 52.8)
CL-00002