2004 SUBARU FORESTER differential

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)

5MT-90
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
10) Remove the 1st driven gear, 2nd driven gear
bushing, gear and hub using ST1 and ST2.
NOTE:
If replace the gear or hub assembly as necessary,
use the new gear & hub assembly as a unit. Do not
attempt to disassemble if at all possible because
they must engage at a specified point. If they
should be disassembled, mark engagement point
beforehand.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
11) Remove the sub gear for 1st driven gear. (Non-
turbo model)
D: ASSEMBLY
1) Install the sleeve and gear and hub assembly by
matching alignment marks.
NOTE:
If replace the gear or hub assembly as necessary,
use the new gear & hub assembly as a unit.
2) Install the washer, snap ring and sub gear to 1st
driven gear.3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
NOTE:
 Take care to install the gear and hub assembly in
proper direction.
 Align the baulk ring and gear & hub assembly
with key convex part.
4) Install the 2nd driven gear bushing onto driven
shaft using ST1, ST2 and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
 Attach a cloth to the end of driven shaft to pre-
vent damage.
 When press fitting, align the oil holes of shaft and
bush.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
5) Install the 2nd driven gear, inner baulk ring, syn-
chro cone, outer baulk ring and insert onto driven
shaft.
(A) 1st gear side
(B) 2nd gear side
(C) Flush surface
(D) Stepped surface
MT-00251
ST1
ST2
MT-00252
(B)
(A)
(C)
(D)
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
MT-00253
ST1
ST2
MT-00254
(A)
(B) (C)(D)

5MT-91
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
6) After installing the key on driven shaft, install the
3rd-4th driven gear using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Align the convex part in baulk ring with insert.
ST 499277200 INSTALLER
7) Install a set of roller bearings onto the driven
shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER
8) Position the woodruff key in groove on the rear
of driven shaft. Install the 5th driven gear onto driv-
en shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER9) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
260 N·m (26.5 kgf-m, 192 ft-lb)
NOTE:
 Stake the lock nut at two points.
 Using the spring balancer, check that starting
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
kgf, 0.02 to 0.33 ft).
10) Install the roller bearing onto drive pinion.
NOTE:
When installing the roller bearing, note its direc-
tions (front and rear) because the knock pin hole in
outer race is offset.
MT-00255
ST
MT-00256
ST
MT-00257
ST
(A) Roller bearing
(B) Knock pin hole
MT-00258
ST
MT-00259
MT-00260
(A)
(B)

5MT-92
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
11) Install the washer using ST1, ST2 and press.
NOTE:
 Discard the old lock nuts, replace with new ones.
 Secure the lock nut in four places.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
12) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.13) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because the spacer must be installed in
proper direction.
(A) Washer
MT-00261
(A)
ST1
ST2
MT-00262
(A) Driven shaft
(B) Drive pinion shaft
(C) Drive pinion collar
(D) Needle bearing (25×30×20)
(E) Adjusting washer No. 2 (25×36×4)
(F) Thrust bearing (25×37.5×3)
(G) Adjusting washer No. 1 (25×36×t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)

5MT-93
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
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.
 The roller bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
 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.
 If the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 — 1.0 mm (0.020 — 0.040 in)
 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.
(A) Drive pinion shaft
(B) Roller bearing
MT-00264
(A)
(B)
MT-00265
(A)
MT-00208

5MT-94
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select the adjusting washer No. 1 so that dimen-
sion (H) is zero through visual check. Position the
washer (18.3×30×4) and lock washer (18×30×2)
and install the lock nut (18×13.5).
2) Using the ST1, ST2 and ST3, tighten the lock nut
to specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 3) After removing the ST2, measure the starting
torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
lb)
4) If the starting torque is not within specified limit,
select a new adjusting washer No. 1 and recheck
starting torque.
MT-00267 (H)
MT-00268
ST1
ST2
ST3
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
MT-00269
ST1
ST3
MT-00270
(A)
(B)