2004 SUBARU FORESTER manual transmission

5MT-82
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Dual-Range
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
 Bearings whose balls, outer races and inner rac-
es are broken or rusty.
 Worn bearings
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
 Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
 When the sliding surface is damaged or abnor-
mally worn.
 When the inner wall is abnormally worn.
3) Gears
 Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
 Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
 Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
 When the inner surface and end face are dam-
aged.
 When the ring inner surface is abnormally or par-
tially worn down.
 When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
F: ADJUSTMENT
Choose the main shaft rear plate. ADJUSTMENT, Main Shaft Assembly For Single-
Range.>

5MT-83
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
19.Input Shaft Assembly
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. 62, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION
1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
3) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
4) Install the drive pinion assembly. 87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
5) Install the transmission case. INSTALLATION, Transmission Case.>
6) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
7) Install the manual transmission assembly on ve-
hicle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the O-ring from input shaft holder. Also,
remove the input shaft holder shim.
NOTE:
 Use a new O-ring.
 Number of shims used varies from none to two.
2) Put vinyl tape around the input shaft splines to
protect oil seal from damage.
3) Remove the inner snap ring.
ST 398663600 PLIERS
4) Hold the input shaft holder stationary and re-
move the input shaft by tapping its end with a plas-
tic hammer.
(A) Input shaft holder
(B) O-ring
(C) Input shaft holder shim
(A) Input shaft holder
(B) Input shaft
MT-00226
(A)(B)
(C)
MT-00227
ST
MT-00228(A)
(B)

5MT-84
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
5) Remove the outer snap ring. Then remove the
oil squeeze plate and straight pin.
6) Remove the snap ring.
7) Using a press and ST, remove the ball bearing.
NOTE:
Remove the inner snap ring before pressing.
ST 498077000 REMOVER
8) Remove the oil seal from input shaft holder.D: ASSEMBLY
1) Install the ball bearing onto input shaft.
NOTE:
Place the snap ring between input shaft gear and
ball bearing beforehand. Use the table at 8) as a
guide in selecting a suitable snap ring.
ST1 899580100 INSTALLER
ST2 399513600 INSTALLER
2) Install the snap ring on input shaft.
3) Inspect the clearance between ball bearing and
snap ring. Shaft Assembly.>
4) Install the straight pin and oil squeeze plate to in-
put shaft.
5) Install the snap ring.
(A) Snap ring
(B) Oil squeeze plate
(A) Snap ring
MT-00229
(A)
(B)
MT-00230
(A)
MT-00231
ST
(A) Snap ring
(A) Straight pin
(B) Oil squeeze plate
MT-00232
ST1
ST2
MT-00230
(A)
MT-00234
(A)
(B)

5MT-85
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
6) Drive the oil seal into input shaft holder.
NOTE:
Apply a coat of grease to sealing lips before install-
ing oil seal.
ST 398507703 DUMMY COLLAR
7) Wind vinyl tape around the shaft splines and in-
sert input shaft into holder by lightly tapping it by
hand.8) Install the snap ring to input shaft holder.
NOTE:
Select a suitable snap ring so that clearance be-
tween snap ring and bearing is held within 0 to 0.12
mm (0 to 0.0047 in).
ST 398663600 PLIERS
9) Install the O-ring to input shaft holder.
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
 Bearings whose balls, outer races and inner rac-
es are broken or rusty.
 Worn bearings
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
 Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
 When the sliding surface is damaged or abnor-
mally worn.
 When the inner wall is abnormally worn.
(A) Vinyl tape
(B) Input shaft
MT-00235
ST
MT-00236
(A)(B)
Snap ring
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
(A) O-ring
(B) Input shaft holder
MT-00227
ST
MT-00238
(A)
(B)

5MT-86
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
3) Gears
 Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
 Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
 Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
 When the inner surface and end face are dam-
aged.
 When the ring inner surface is excessively or
partially worn down.
 When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
Clearance:
0 — 0.12 mm (0 — 0.0047 in)
If the measurement is not within specification, se-
lect a suitable snap ring.F: ADJUSTMENT
1) Place transmission main shaft assembly and in-
put shaft on transmission main case without shim.
2) The proper number of shim can be determined
as follows:
D = A−(B+C)
A: Main case length (353 mm (13.90 in)
B: Input shaft complete length
C: Main shaft assembly length
NOTE:
The thickness of shim is 0.45 to 0.55 mm (0.0177 to
0.0217 in).
(A) Snap ring
Snap ring
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
MT-00239
(A)
Dimension “D” mm (in) Number of shims
52.50 — 53.11 (2.0669 — 2.0909) —
52.00 — 52.49 (2.0472 — 2.0665) 1
51.26 — 51.99 (2.0181 — 2.0468) 2
MT-01015
CB

5MT-87
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
20.Drive Pinion Shaft Assembly
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. 62, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B: INSTALLATION
1) Remove the differential assembly.
2) Alignment marks/numbers on hypoid gear set:
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no low-
er number is shown, the value is zero. The number
on hypoid driven gear indicates a number for com-
bination with drive pinion.3) Place the drive pinion shaft assembly on right
hand transmission main case without shim and
tighten the bearing mounting bolts.
4) Inspection and adjustment of ST:
NOTE:
 Loosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the
scale end are on the same level.
 Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE
ASSY
5) Position the ST by inserting the knock pin of ST
into the knock hole in transmission case.
ST 499917500 DRIVE PINION GAUGE
ASSY
6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE
ASSY
7) The thickness of shim shall be determined by
adding the value indicated on drive pinion to the
value indicated on ST. (Add if the number on drive
pinion is prefixed by + and subtract if the number is
prefixed by−.)
ST 499917500 DRIVE PINION GAUGE
ASSY
(A) Main shaft assembly
(B) Drive pinion shaft assembly
(A) Match number
(B) Shim adjust number
MT-00161
(A)
(B)
MT-00241
(A)
(B)
(A)
+0.1
(A) Plate
(B) Scale
(A) Adjust clearance to zero without shim.
MT-00242
(A)
(B)
ST
MT-00243
(A)ST

5MT-88
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
8) Select one to three shims from the next table for
the value determined as described above and take
a shim thickness which is closest to the indicated
value.
9) Install the differential assembly. 96, INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st-2nd, 3rd-4th
and 5th shifter fork so that coupling sleeve and re-
verse driven gear are positioned in the center of
their synchronizing mechanisms. INSPECTION, Drive Pinion Shaft Assembly.>
11) Install the transmission case. INSTALLATION, Transmission Case.>
12) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
13) Install the manual transmission assembly to ve-
hicle. sembly.>C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disas-
sembly or reassembly to prevent damage.
1) Straighten the lock nut at staked portion. Re-
move the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
2) Withdraw the drive pinion from driven shaft.
Remove the differential bevel gear sleeve, adjust-
ing washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.
Drive pinion shim
Part No. Thickness mm (in)
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
(A) Differential bevel gear sleeve
(B) Adjusting washer No. 1 (25×37.5×t)
(C) Thrust bearing (25×37.5×3)
(D) Adjusting washer No. 2 (25×37.5×4)
(E) Needle bearing (25×30×20)
(F) Drive pinion collar
(G) Needle bearing (30×37×23)
(H) Thrust bearing (33×50×3)
ST1
ST2
MT-00244
ST3
MT-00245
(B)
(D)(C)(A) (F)
(H)(G)(E)

5MT-89
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
3) Remove the roller bearing and washer using ST
and press.
NOTE:
Do not reuse the roller bearing.
ST 498077000 REMOVER
4) Straighten the lock nut at staked portion. Re-
move the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
5) Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOV-
ER6) Remove the woodruff key.
7) Remove the roller bearing, 3rd-4th driven gear
using ST1 and ST2.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
8) Remove the key.
9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
MT-00246
ST
MT-00247
ST1ST2
MT-00248
ST
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
MT-00249
ST1
ST2
MT-00250
(A)
(B) (C)(D)