2004 SUBARU FORESTER Service Repair Manual

compression ratio steering timing belt key fob reset sun roof climate settings

Page 2713 of 2870

SUBARU FORESTER 2004 Service Repair Manual MANUAL TRANSMISSION AND
DIFFERENTIAL
5MT
Page
1. General Description ....................................................................................2
2. Transmission Gear Oil ....................

MANUAL TRANSMISSION AND
DIFFERENTIAL
5MT
Page
1. General Description ....................................................................................2
2. Transmission Gear Oil ..............................................................................31
3. Manual Transmission Assembly ...............................................................32
4. Transmission Mounting System ................................................................39
5. Oil Seal......................................................................................................41
6. Differential Side Retainer Oil Seal.............................................................42
7. Switches and Harness ..............................................................................43
8. Vehicle Speed Sensor...............................................................................46
9. Preparation for Overhaul ...........................................................................47
10. Oil Pump ...................................................................................................48
11. Transfer Case and Extension Case Assembly..........................................50
12. Transfer Drive Gear ..................................................................................54
13. Transfer Driven Gear ................................................................................56
14. Center Differential .....................................................................................58
15. Reverse Check Sleeve..............................................................................59
16. Transmission Case ...................................................................................62
17. Main Shaft Assembly For Single-Range ...................................................69
18. Main Shaft Assembly For Dual-Range ......................................................77
19. Input Shaft Assembly ................................................................................83
20. Drive Pinion Shaft Assembly .....................................................................87
21. Front Differential Assembly .......................................................................96
22. Speedometer Gear..................................................................................103
23. Reverse Idler Gear ..................................................................................104
24. Shifter Fork and Rod ...............................................................................106
25. Counter Gear ..........................................................................................109
26. General Diagnostic..................................................................................111

Page 2714 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil
Model2.0 L Non-

Page 2715 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of ma

5MT-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of main shaft rear plate
Snap ring to counter washer clearance :
0.05 — 0.35 mm (0.0020 — 0.0138 in)
Input shaft holder adjustment
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque :
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6
ft-lb)
5. INPUT SHAFT ASSEMBLY
Snap ring (Outer-28) to ball bearing clear-
ance :
0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Inner-68) to bearing clearance :
0 — 0.12 mm (0 — 0.0047 in)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub
clearance :
0.060 — 0.100 mm (0.0024 — 0.0039 in)
Drive pinion shim
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
32295AA0310.150
(0.0059) 32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069) 32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079) 32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089) 32295AA1010.500
(0.0197)
Main shaft rear plate
Dimension “A” mm (in) Part No. Mark
4.00 — 4.13
(0.1575 — 0.1626) 32294AA041 1
3.87 — 3.99
(0.1524 — 0.1571) 32294AA051 2
Snap ring (Outer-19)
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
Dimension “D” mm (in) Number of shim
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
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)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
Snap ring (Inner-68)
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
Snap ring (Outer-25)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)

Page 2716 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH)
wall clearance :
6.0 — 7.

5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH)
wall clearance :
6.0 — 7.5 mm (0.236 — 0.295 in)
After installing a suitable reverse shifter lever, ad-
just the clearance using washers.
Reverse idler gear to transmission case wall
clearance:
0 — 0.5 mm (0 — 0.020 in)
8. SHIFTER FORK AND ROD
Select the suitable shifter forks so that both cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance :
A: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
B: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
9. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Reverse check plate adjustment
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall
Washer (20.5×26×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059) — —
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3 Approach to 2nd gear
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3 Approach to 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA211 No mark Standard
32812AA221 9Become distant from
5th gear by 0.2 mm
(0.008 in)
5th shifter fork (Turbo)
Part No. Mark Remarks
32812AA231 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in)
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA130 SNeutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 UNeutral position is
closer to reverse gear.
Reverse check plate
Par t No. Mar kAngle
θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.

Page 2717 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-5
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
10.EXTENSION ASSEMBLY
Thrust washer (50×61×t) to taper roller bearing
table outer race side clearance :
0.2 — 0.3 mm (0.0008 — 0.0

Page 2718 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-6
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
B: COMPONENT
1. TRANSMISSION CASE
MT-00002
T(3) (1)
(2)
(4) (5)
(12) (10) (11)
(18)
(13)
(9)
(8)
(7)
(6)
(16) (14)
(15)(17)

Page 2719 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-7
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
Transmission case tightening torque
(1) Transmission case ASSY (Single-
range)(9) Oil seal (16) High-low cable bracket A (Dual-
range)

Page 2720 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-8
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. DRIVE PINION ASSEMBLY
(1) Drive pinion shaft (14) 1st driven gear (28) Lock washer
(2) Roller bearing (15) Baulk ring (29) Lock nut
(3

Load next 8 pages

Page: < prev 1-10 ... 2681-2688 2689-2696 2697-2704 2705-2712 2713-2720 2721-2728 2729-2736 2737-2744 2745-2752 ... 2872 next >

navigation update spark plugs buttons brake rotor air bleeding oil level