2004 SUBARU FORESTER Service Repair Manual

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Page 2809 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-96
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
21.Front Differential Assembly
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Man

Page 2810 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-97
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Loosen the twelve bolts and remove the hypoid
driven gear.
2) Drive out the stra

Page 2811 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-98
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
2. SIDE RETAINER
NOTE:
Replace the oil seal and O-ring after adjustment of
drive pinion gear backlash and tooth contact.
1) Remo

Page 2812 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-99
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
4) Install the roller bearing to differential case.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp t

Page 2813 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-100
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
The hypoid drive gear and drive pinion shaft

Page 2814 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-101
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
3. TOOTH CONTACT OF HYPOID GEAR
Check the tooth contact of hypoid gear as follows:
Apply a uniform thin coat of red lead on bot

Page 2815 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-102
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height

Page 2816 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-103
MANUAL TRANSMISSION AND DIFFERENTIAL
Speedometer Gear
22.Speedometer Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission Asse

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