2004 SUBARU FORESTER Service Repair Manual

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Page 2801 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

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)

Page 2802 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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) Strai

Page 2803 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 assemb

Page 2804 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 e

Page 2805 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

Page 2806 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

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

Page 2807 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 chec

Page 2808 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-95
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
5) If the specified starting torque range cannot be
obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2

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