2004 SUBARU FORESTER Service Repair Manual

key fob battery fuse diagram warning light clock setting fuel tank capacity drain bolt

Page 2817 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-104
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
23.Reverse Idler Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission

5MT-104
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
23.Reverse Idler Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. es and Harness.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
4) Remove the transmission case. 62, REMOVAL, Transmission Case.>
5) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) Remove the main shaft assembly.
Single-Range model
For Single-Range.>
Dual-Range model
For Dual-Range.>
7) Remove the differential assembly. 96, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. 106, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the Rev
idler gear shaft, reverse idler gear and washer.
10) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse shifter lever, reverse idler
gear and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall. to 5MT-104, INSTALLATION, Reverse Idler Gear.>
and Idler Gear.>
3) Install the shifter forks and rods. 106, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. 96, INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
Single-Range model
sembly For Single-Range.>
Dual-Range model
sembly For Dual-Range.>
6) Install the drive pinion shaft assembly. 5MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
7) Install the transmission case. INSTALLATION, Transmission Case.>
8) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
9) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
10) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
(A) Straight pin
(B) Rev idler gear shaft
(C) Rev idler gear
(D) Washer
MT-00303
(A)(B)
(C)
(D)
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
MT-00304
(A)
(B)
(D)
(C)

Page 2818 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-105
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
C: INSPECTION
1) Move the reverse shifter rod toward the reverse
side. Inspect the clearance between reverse idler
gear and transmission

Page 2819 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-106
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
24.Shifter Fork and Rod
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmiss

5MT-106
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
24.Shifter Fork and Rod
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. es and Harness.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
4) Remove the transmission case. 62, REMOVAL, Transmission Case.>
5) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) Remove the main shaft assembly.
Single-Range model
For Single-Range.>
Dual-Range model
For Dual-Range.>
7) Remove the differential assembly. 96, REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin with ST, and 5th shifter
fork.
ST 398791700 STRAIGHT PIN REMOVER
9) Remove the plugs, springs and checking balls.10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
NOTE:
When removing the rod, keep other rods in neutral.
11) Drive out the straight pin, and pull out 1st-2nd
fork rod and shifter fork.
12) Remove the outer snap ring, and pull out the
reverse shifter rod arm from reverse fork rod. Then
take out the ball, spring and interlock plunger from
rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be
careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
B: INSTALLATION
1) Apply grease to plunger.
ST 399411700 ACCENT BALL INSTALLER
2) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into hole in reverse fork rod arm, and
hold it with outer snap ring using ST.
3) Position the ball, spring and new gasket in re-
verse shifter rod hole, on left side transmission
case, and tighten the checking ball plug.
4) Install the 1st-2nd fork rod into 1st-2nd shifter
fork via the hole on the rear of transmission case.
5) Align the holes in rod and fork, and new drive
straight pin into these holes using ST.
NOTE:
Set other rods to neutral.
Make sure the interlock plunger is on the 3rd-4th
fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
6) Apply a coat of grease to plunger.
7) Install the interlock plunger onto 3rd-4th fork rod.
8) Install the 3rd-4th fork rod into 3rd-4th shifter fork
via the hole on the rear of transmission case.
(A) Straight pin
(B) 5th shifter fork
MT-00309(A) (B)
(A) Straight pin
(B) 3rd-4th fork rod
(C) Shifter fork
MT-00310(A)
(B) (C)

Page 2820 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-107
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
9) Align the holes in rod and fork, and new drive
straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make s

5MT-107
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
9) Align the holes in rod and fork, and new drive
straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make sure the interlock plunger (installing be-
fore) is on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
10) Install the 5th shifter fork onto the rear of re-
verse fork rod. Align holes in the two parts and new
drive straight pin into place.
ST 398791700 STRAIGHT PIN REMOVER
11) Position the balls, checking ball springs and
new gaskets into 3rd-4th and 1st-2nd fork rod
holes, and install plugs.
12) Install the differential assembly. 96, INSTALLATION, Front Differential Assembly.>
13) Install the main shaft assembly.
Single-Range model
sembly For Single-Range.>
Dual-Range model
sembly For Dual-Range.>14) Install the drive pinion shaft assembly. 5MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
15) Install the transmission case. INSTALLATION, Transmission Case.>
16) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
17) Install the back-up light switch and neutral po-
sition switch. Switches and Harness.>
18) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism:
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
MT-00311(C) (A) (B)
MT-00311(C) (A) (B)(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in).
32804AA070 — Standard
32804AA080 3Approach to 2nd gear
by 0.2 mm (0.008 in).
MT-00313
(A)
(B)
(C) (a)(b)

Page 2821 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-108
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
4) Inspect the clearance between 3rd, 4th drive
gear and coupling sleeve. If any clearance is not
within specifications, replace the s

Page 2822 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-109
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
25.Counter Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-32, REMOVAL, Manual
Transmission Assembly.>
2

Page 2823 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-110
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
C: INSPECTION
1) After installing the snap ring, measure the clear-
ance between snap ring and counter washer.
Clearance:
0.05 — 0.35 mm (0.

Page 2824 of 2870

SUBARU FORESTER 2004 Service Repair Manual 5MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
26.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
N
OTE:
T

5MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
26.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
N
OTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gearReplace.
(b) Worn, damaged or burred chamfer of
spline of gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wear Correct or replace.
2. Gear slips out.
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail springReplace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeveReplace.
(f) Worn tooth step of synchronizer hub Replace.
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and 2nd bush Replace.
(i) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis-
sion.
N
OTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.Replace.

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