differential SUBARU FORESTER 2004 Service Manual Online

5MT-16
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
9. TRANSMISSION MOUNTING
(1) Pitching stopper (8) Cushion DTightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmemberT1: 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plateT2: 35 (3.6, 26)
(4) Front plate (11) Front crossmemberT3: 50 (5.1, 36.9)
(5) Dynamic damperT4: 58 (5.9, 43)
(6) Rear cushion rubberT5: 70 (7.1, 51)
(7) Rear crossmemberT6: 140 (14.3, 103)
(1)
T4
T1
T5
T5
T5
T2
T6
T2
T3
(2)
(4)
(6)
(8)
(9)
(8)(3)
(2)
(10)
(7)
(5)
(3)
(11)
MT-00010

5MT-17
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation, and disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
 Be careful not to burn your hands, because each
part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply gear oil onto sliding or revolution surfaces
before installation.
 Replace deformed or otherwise damaged snap
rings with new ones.
 Before installing O-rings or oil seals, apply suffi-
cient amount of gear oil to avoid damage and defor-
mation.
 Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vis e.
 Avoid damaging the mating surface of the case.
 Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
399411700 ACCENT BALL
INSTALLERUsed for installing reverse shifter rail arm.
899524100 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) PULLER
(2) CAP
ST-399411700
ST-899524100

5MT-18
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
399780104 WEIGHT Used for measuring preload on roller bearing.
498077000 REMOVER Used for removing roller bearing of drive pinion
shaft.
498077300 CENTER DIFFER-
ENTIAL BEARING
REMOVERUsed for removing the center differential cover
ball bearing.
498147000 DEPTH GAUGE Used for adjusting main shaft axial end play. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-399780104
ST-498077000
ST-498077300
ST-498147000

5MT-19
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498247001 MAGNET BASE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with DIAL GAUGE (498247100).
498247100 DIAL GAUGE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with MAGNET BASE (498247001).
498427400 STOPPER Used for securing the drive pinion shaft assem-
bly and driven gear assembly when removing the
drive pinion shaft assembly lock nut.
498787100 MAIN SHAFT
STOPPERUsed for removing and installing transmission
main shaft lock nut. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498247001
ST-498247100
ST-498247400
ST-498787100

5MT-20
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498937000 TRANSMISSION
HOLDERUsed for removing and installing transmission
main shaft lock nut.
499277100 BUSH 1-2
INSTALLER Used for installing 1st driven gear thrust plate
and 1st-2nd driven gear bush.
 Used for installing roller bearing outer races to
differential case.
499277200 INSTALLER Used for press-fitting the 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.
499757002 INSTALLER  Used for installing snap ring (OUT 25), and
ball bearing (25×26×17).
 Used for installing bearing cone of transfer
driven gear (extension core side). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498937000
ST-499277100
ST-499277200
ST-499757002

5MT-21
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
499827000 PRESS Used for installing speedometer oil seal when
installing speedometer cable to transmission.
499857000 5TH DRIVEN GEAR
REMOVERUsed for removing 5th driven gear.
499877000 RACE 4-5
INSTALLER Used for installing 4th needle bearing race and
ball bearing onto transmission main shaft.
 Used with REMOVER (899714110). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499787000
ST-499827000
ST-499857000
ST-499877000

5MT-22
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499917500 DRIVE PINION
GAUGE ASSYUsed for adjusting drive pinion shim.
499927100 HANDLE Used for fitting transmission main shaft.
499937100 TRANSMISSION
STAND SETStand used for transmission disassembly and
assembly.
499987003 SOCKET WRENCH
(35)Used for removing and installing driven pinion
lock nut and main shaft lock nut. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499917500
ST-499927100
ST-499937100
ST-499987003

5MT-23
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499987300 SOCKET WRENCH
(50)Used for removing and installing driven gear
assembly lock nut.
899714110 REMOVER Used for fixing transmission main shaft, drive
pinion, rear drive shaft.
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
899884100 HOLDER Used for tightening lock nut on sleeve. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499987300
ST-899714110
ST-899864100
ST-899884100

5MT-24
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899904100 REMOVER Used for removing and installing straight pin.
899988608 SOCKET WRENCH
(27)Used for removing and installing drive pinion lock
nut.
398497701 ADAPTER  Used for installing roller bearing onto differen-
tial case.
 Used with INSTALLER (499277100).
499587000 INSTALLER Used for installing driven gears to driven shaft. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899904100
ST-899988608
ST-398497701
ST-499587000

5MT-25
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899824100 PRESS Used for installing speedometer shaft oil seal.
499987100 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
899984103 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
498057300 INSTALLER Used for installing extension oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899824100
ST-499987100
ST-899984103
ST-498057300