2004 SUBARU FORESTER manual transmission

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

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-69
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
17.Main Shaft Assembly For Sin-
gle-Range
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 transmission case. 50, REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
B: INSTALLATION
1) Wrap the clutch splined section with vinyl tape to
prevent damage to oil seal.
2) Apply grease Unilube #2 (or equivalent) to the
sealing lip of oil seal.
3) Install the needle bearing and new oil seal onto
the front of transmission main shaft assembly.
4) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
5) Install the drive pinion assembly. 87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
6) Install the transmission case. INSTALLATION, Transmission Case.>
7) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
8) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: DISASSEMBLY
1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
NOTE:
Unlock the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3) Remove the 5th-Rev sleeve and hub assembly,
5th baulk ring, 5th drive gear and needle bearing.
4) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
MT-00185
(A)
(A) 5th-Rev sleeve and hub ASSY
(B) 5th baulk ring
(C) 5th drive gear
(A) Synchro cone stopper
(B) Snap ring
MT-00186ST2ST1
MT-00187
(A) (B) (C)
MT-00188
(A) (B)

5MT-70
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
5) Using the ST1, ST2 and a press, remove the ball
bearing, synchro cone and baulk ring (Rev).
NOTE:
If replace the sleeve or hub assembly as neces-
sary, use the new sleeve & hub assembly as a unit.
Do not disassemble because they must engage at
a specified point. If they should be disassembled,
mark engagement point on splines beforehand.
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOV-
ER6) Using the ST1 and ST2, remove rest of the
parts.
NOTE:
If replace the sleeve or hub assembly as neces-
sary, use the new sleeve & hub assembly as a unit.
Do not disassemble because they must engage at
a specified point. If they should be disassembled,
mark engagement point on splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
(A) Ball bearing
(B) Revers synchro cone
(C) Revers baulk ring
MT-00189
(B)
(A)
(C)ST2
ST1
(A) Press
MT-00190
(A)
ST2
ST1

5MT-71
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
D: ASSEMBLY
1. NON-TURBO MODEL
1) Assemble each sleeve and hub assembly.
2) Install the 3rd drive gear, outer baulk ring, 3rd
synchro cone, inner baulk ring, 3rd-4th sleeve and
hub assembly for 3rd needle bearing on transmis-
sion main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4) Install the 4th baulk ring, 4th needle bearing, 4th
drive gear and 4th gear thrust washer to transmis-
sion main shaft.
NOTE:
 Align the baulk ring and gear & hub assembly
with key convex part.
 Pay attention to the orientation of thrust washer.
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th-Rev hub ASSY
(D) 5th gear side
MT-00191 (D) (C)(B) (A)
(A) 4th needle bearing race
(A) Groove
(B) Face this surface to 4th gear side
MT-00192 (A)
ST1
ST2
MT-00193 (A)
(B)

5MT-72
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
5) Drive the ball bearing onto the rear section of
transmission main shaft using ST1, ST2 and a
press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6) Using the ST1 and ST2, install the 5th gear
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Pay attention to the orientation of thrust washer.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7) Install the bearing onto synchro cone.
8) Install the Rev baulk ring, Rev synchro cone and
new ball bearing. onto 5th-Rev sleeve and hub as-
sembly using ST and a press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).9) After press fitting, make sure the synchro cone
rotates freely.
ST 499757002 INSTALLER
10) Install the synchro cone stopper and snap ring
to 5th-Rev sleeve and hub assembly.
(A) Face this surface to 5th gear side.
MT-00194
ST1
ST2
MT-00195
(A)
(A) Rev Baulk ring
(B) Rev Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
(B) (A)
(C)
ST
MT-00188
(A) (B)

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)