2004 SUBARU FORESTER differential

5MT-63
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
4) Remove the input shaft holder.
5) Remove the high-low switch. REMOVAL, Switches and Harness.>
6) Using the ST, drive out the straight pin, and re-
move high-low shifter lever.
ST 398791700 STRAIGHT PIN REMOVER 2
NOTE:
When driving out the straight pin, remove it in the
direction that it does not butt against transmission
case.
7) Remove the main shaft rear plate.8) Separate the transmission case into right and
left cases by loosening the seventeen coupling
bolts and nuts.
9) Using a hammer handle, etc. remove the drive
pinion shaft assembly from left side transmission
case, and then remove the main shaft assembly.
10) Removing high-low shifter fork:
Remove the high-low shifter fork together with
high-low shifter shaft and washer.
NOTE:
Be careful not to drop the two high-low shifter piec-
es.
(A) Input shaft holder
(B) Input shaft
(A) Straight pin
(B) High-low shifter lever
(A) Main shaft rear plate
MT-00163
(A)
(B)
MT-00164
(A)
(B)
ST
MT-00165
(A)
(A) Main shaft ASSY
(B) Drive pinion shaft ASSY
(A) High-low shifter fork
(B) Input shaft ASSY
MT-00160
MT-00161
(A)
(B)
MT-00169(B) (A)

5MT-64
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
11) Remove the main shaft assembly and input
shaft assembly.
NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.
12) Remove the differential assembly.
NOTE:
 Be careful not to confuse the right and left roller
bearing outer races.
 Be careful not to damage the retainer oil seal.
B: INSTALLATION
1. SINGLE-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.
Install the needle bearing knock pin hole into trans-
mission 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 (Part No. : 004403007) or
equivalent6) Tighten the seven teen 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 drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
 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 (0.39 in) 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)
(A) Main shaft ASSY
(B) Input shaft ASSY
MT-00170
(A)
(B)
MT-00162
(9)(7)
(5)
(1)
(2)(16)
(17)
(11)
(3)
(4)
(12)
(8) (6) (10) (14) (15)(13)
MT-00172
MT-00158

5MT-65
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
8) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing:
NOTE:
Support the drive pinion assembly with ST.
ST 498427100 STOPPER
9) Place the transmission with case left side facing
downward and put ST1 on bearing outer race.
10) 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 HANDLE11) 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
12) 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.
13) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. TION, Front Differential Assembly.>
MT-00174ST
MT-00175
ST3ST2
ST1
MT-00176
ST

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