2004 SUBARU FORESTER lock

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)

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) Straighten the lock nut at staked portion. Re-
move the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
5) Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOV-
ER6) Remove the woodruff key.
7) Remove the roller bearing, 3rd-4th driven gear
using ST1 and ST2.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
8) Remove the key.
9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
MT-00246
ST
MT-00247
ST1ST2
MT-00248
ST
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
MT-00249
ST1
ST2
MT-00250
(A)
(B) (C)(D)

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 excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Align the convex part in baulk ring with insert.
ST 499277200 INSTALLER
7) Install a set of roller bearings onto the driven
shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER
8) Position the woodruff key in groove on the rear
of driven shaft. Install the 5th driven gear onto driv-
en shaft using ST and press.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER9) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
260 N·m (26.5 kgf-m, 192 ft-lb)
NOTE:
 Stake the lock nut at two points.
 Using the spring balancer, check that starting
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
kgf, 0.02 to 0.33 ft).
10) Install the roller bearing onto drive pinion.
NOTE:
When installing the roller bearing, note its direc-
tions (front and rear) because the knock pin hole in
outer race is offset.
MT-00255
ST
MT-00256
ST
MT-00257
ST
(A) Roller bearing
(B) Knock pin hole
MT-00258
ST
MT-00259
MT-00260
(A)
(B)

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 in four places.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
12) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.13) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because the spacer must be installed in
proper direction.
(A) Washer
MT-00261
(A)
ST1
ST2
MT-00262
(A) Driven shaft
(B) Drive pinion shaft
(C) Drive pinion collar
(D) Needle bearing (25×30×20)
(E) Adjusting washer No. 2 (25×36×4)
(F) Thrust bearing (25×37.5×3)
(G) Adjusting washer No. 1 (25×36×t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)

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 check. Position the
washer (18.3×30×4) and lock washer (18×30×2)
and install the lock nut (18×13.5).
2) Using the ST1, ST2 and ST3, tighten the lock nut
to specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 3) After removing the ST2, measure the starting
torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
lb)
4) If the starting torque is not within specified limit,
select a new adjusting washer No. 1 and recheck
starting torque.
MT-00267 (H)
MT-00268
ST1
ST2
ST3
(A) Adjusting washer No. 1
(B) Adjusting washer No. 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)
MT-00269
ST1
ST3
MT-00270
(A)
(B)

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 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
6) Recheck that the starting torque is within speci-
fied range, then clinch the lock nut at four positions.
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
MT-00270
(A)
(B)

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) Remove the O-ring.
2) Remove the oil seal.
NOTE:
 Remove the oil seal using a flat tip screwdriver
 Do not reuse the oil seal. Prepare a new oil seal.
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the differential bevel gear and bevel pin-
ion together with washers, and insert pinion shaft.
NOTE:
Face the chamfered side of washer toward gear.2) Measure the backlash between differential bevel
gear and pinion. If it is not within specifications, in-
stall a suitable washer to adjust it. 101, ADJUSTMENT, Front Differential Assembly.>
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) Align the pinion shaft and differential case at
their holes, and drive the straight pin into holes
from the hypoid driven gear side, using ST.
NOTE:
Lock the straight pin after installing.
ST 899904100 REMOVER
(A) Differential bevel pinion
(B) Differential bevel gear
(C) Pinion shaft
MT-00279
MT-01003
MT-00284
(A) (B)
(C)
(A) Pinion shaft
(B) Differential case
(C) Straight pin
MT-00285
ST1
ST2
MT-00286
(A)
(C)
(B)

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
tooth surface are damaged, excessively worn, or
seized.
 The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
 There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
 The differential case has worn or damaged slid-
ing surfaces.
1. DIFFERENTIAL BEVEL PINION GEAR
BACKLASH
Measure the backlash between differential bevel
gear and pinion. If it is not within specifications, in-
stall a suitable washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
2) Install the axle shaft (SUBARU Genuine Parts)
to both sides, move it clockwise and counter clock-
wise to contact tooth, and then read the value of
dial gauge runout.
Parts No. 38415AA100 AXEL SHAFT
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) If the backlash is outside specified range, adjust
it by turning the holder in right side case.
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H) (I)
(H)MT-00285
ST1
ST2
MT-00293ST1
ST2ST3