2004 SUBARU FORESTER lock

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)

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)

CL-14
CLUTCH SYSTEM
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Use SUBARU genuine fluid, grease etc. or the
equivalent. Do not mix fluid, grease etc. with that of
another grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply grease onto sliding or revolution surfaces
before installation.
 Before installing O-rings or snap rings, apply suf-
ficient amount of fluid to avoid damage and defor-
mation.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
 Keep fluid away from the vehicle body. If any flu-
id contacts the vehicle body, immediately flush the
area with water.

CL-26
CLUTCH SYSTEM
Master Cylinder
6. Master Cylinder
A: REMOVAL
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal.
3) Remove the air cleaner case and air intake duct
(Non-turbo model). AL, Air Cleaner Case.> MOVAL, Air Intake Duct.>
4) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the paint surface; wipe it off quickly if spilt.
B: INSTALLATION
1) Install the master cylinder to body, and install the
clutch pipe to master cylinder.
NOTE:
Check that the pipe is routed properly.
Tightening torque:
T1: 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
T2: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Apply a coat of grease to the clevis pin.
3) Connect the push rod of master cylinder to
clutch pedal, and install the new clevis pin and
snap pin.
4) After bleeding air from the system, ensure that
clutch operates properly.

5) Install the air cleaner case and air intake duct
(Non-turbo model). LATION, Air Cleaner Case.> INSTALLATION, Air Intake Duct.>
6) Install the intercooler (Turbo model). IN(H4DOTC)-11, INSTALLATION, Intercooler.>
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
CL-00042
(A)
(B)
(C)(D)
CL-00137
(A) Clevis pin
(B) Snap pin
(C) Push rod
CL-00163
T2T1
CL-00045
(A)
(B)
(C)

CL-34
CLUTCH SYSTEM
Clutch Pedal
10.Clutch Pedal
A: REMOVAL
1. LHD MODEL
1) Remove the steering column. REMOVAL, Tilt Steering Column.>
2) Disconnect the connectors from stop light switch
and clutch switch.
3) Remove the snap pins which secure lever to
push rod and operating rod.
4) Remove the clevis pins which secure lever to
push rod and operating rod.
5) Remove the accelerator pedal. SP(H4SO)-4, REMOVAL, Accelerator Pedal.>
6) Remove the air cleaner case and intake duct.
(Non-turbo model) AL, Air Cleaner Case.> MOVAL, Air Intake Duct.>
7) Remove the intercooler. (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>
8) Remove the PHV adjusting nut and lock nut.
(Model with hill holder)9) Remove the cable clamp, and disconnect the
PHV cable from PHV. (Model with hill holder)
CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
10) Remove the nut which secures clutch master
cylinder.
11) Remove the bolts and nuts which secure brake
and clutch pedals, and remove the pedal assembly.
(A) Operating rod
(B) Push rod
(C) Snap pin
(D) Clevis pin
(A) Adjusting nut
(B) Lock nut
(C) PHV
(D)
(B)(C)
(C) (D)(A)
CL-00090
CL-00091
(C)(B) (A)
(A) PHV cable
(B) Clamp
(B) (A)
CL-00092
CL-00093

CL-35
CLUTCH SYSTEM
Clutch Pedal
2. RHD MODEL
1) Disconnect the ground cable from battery.
2) Loosen the screws and clips, and then remove
the lower cover.
3) Disconnect the clutch switch connector. (Model
with cruise control system)
4) Remove the snap pin connecting clutch pedal
and clutch master cylinder rod, and then pull the
clevis pin out.
5) Remove the clutch master cylinder mounting
nut.
6) Remove the PHV adjusting nut and the lock nut.
(Model with hill holder)
7) Remove the cable clamp, and disconnect the
PHV cable from PHV. (Model with hill holder)CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
8) Remove the clutch pedal bracket.
B: INSTALLATION
1) Install the clutch pedal bracket.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Install the clutch master cylinder mounting nut.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
3) Insert the new clevis pin to assist rod A, and then
install the snap pin.
NOTE:
Apply a coat of grease to the clevis pin.
4) Adjust the stroke amount of clutch pedal. to CL-37, ADJUSTMENT, Clutch Pedal.>
5) Adjust the hill holder (Model with hill holder).

6) Connect the clutch switch connector. (Model
with cruise control system)
7) Install the instrument panel lower cover.
(A) Master cylinder
(A) Adjusting nut
(B) Lock nut
(C) PHV
CL-00072
CL-00164
(A)
CL-00091
(C)(B) (A)
(A) PHV cable
(B) Clamp
(A) Clutch pedal bracket
(B) Clutch pedal
(B) (A)
CL-00092
( A )
( B )
CL-00126

CL-38
CLUTCH SYSTEM
Clutch Pedal
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nut.
4) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.5) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
 Model without cruise control
 Model with cruise control
6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
7) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)
(A) Stopper
(B) Stopper bolt
(A) Clutch switch
(B) Stopper
(C) Clearance
(A) Accelerator pedal
(B) Clevis
(A)
(B)
CL-00131
(A)
(B) (C)
CL-00132
CL-00101
(B)
(A)

CL-39
CLUTCH SYSTEM
Clutch Pedal
9) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
10) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
130 — 135 mm (5.12 — 5.31 in)
11) Install the clutch switch. STALLATION, Clutch Switch.>
2. RHD MODEL
1) Measure the full stroke amount of clutch pedal.
NOTE:
 Measure the length between seat cushion front
end and center portion of clutch pedal.
 Slide the seat at seventh notch from first notch.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) If the stroke amount can not be adjusted by stop-
per nut, remove the clutch switch. REMOVAL, Clutch Switch.>4) Loosen the push rod lock nut.
5) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.
(A) Clutch (Full stroke condition)
(B) Scale
(C) Seat
CL-00078(A)(B)(C)A
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)