2004 SUBARU FORESTER manual transmission

5MT-43
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
7. Switches and Harness
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case.

Case.>
3) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
4) Disconnect the connector of back-up light switch
and neutral position switch.
 Non-turbo model
 Turbo model
5) Lift-up the vehicle.6) Remove the back-up light switch and neutral po-
sition switch with harness.
2. HIGH-LOW SWITCH
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and cleaner case. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> to IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the connector of high-low switch.
4) Remove the high-low switch cable from clamp.
5) Remove the high-low switch.
(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
MT-00107
(B)
(C)
(A)
MT-00105
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
(A) Clamp
(B) High-low switch
MT-00106
(A)
(B)
MT-00107
(B)
(C)
(A)
MT-00108
(B)(A)

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-45
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch. SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model:
Turbo model:
 Non-turbo model
 Turbo model
4) Replace defective parts.
3. HIGH-LOW SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
4) Replace the defective parts.
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3Less than 1 Ω
Other positions More than 1 MΩ
MT-00110
1 2
MT-00111
1 2
3 4
Gear shift position Terminal No. Specified resistance
LO position
1 and 2Less than 1 Ω
HIGH position More than 1 MΩ
MT-00112
1 2

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

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-50
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
11.Transfer Case and Extension
Case Assembly
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.
4) Remove the shifter arm.
5) Remove the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.2) Remove the bearing outer race from extension
case.
3) While pressing the bearing outer race horizontal-
ly, turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
5) Measure the depth “X”.
NOTE:
Measure with bearing cone and thrust washer re-
moved.
6) Calculate the space “t” using the following equa-
tion: t = X−W+0.2 to 0.3 mm (0.008 to 0.012 in)
7) Select the nearest washer in the following table:
Standard clearance between thrust washer and
taper roller bearing:
0.2 — 0.3 mm (0.008 — 0.012 in)
NOTE:
Set the clearance within standard clearance.
MT-00116
MT-00117
MT-00118
(A) Bearing outer race
(B) Extension case
MT-00119
(B)
(A)
MT-00120
W
MT-00121
X