2004 SUBARU FORESTER Service Repair Manual

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Page 2777 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 separ

Page 2778 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 498427

Page 2779 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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. F

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

Page 2780 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

Page 2781 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 t

Page 2782 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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. <Ref. to

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)

Page 2783 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 sle

Page 2784 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 ri

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