2004 SUBARU FORESTER manual transmission

5MT-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of main shaft rear plate
Snap ring to counter washer clearance :
0.05 — 0.35 mm (0.0020 — 0.0138 in)
Input shaft holder adjustment
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque :
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6
ft-lb)
5. INPUT SHAFT ASSEMBLY
Snap ring (Outer-28) to ball bearing clear-
ance :
0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Inner-68) to bearing clearance :
0 — 0.12 mm (0 — 0.0047 in)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub
clearance :
0.060 — 0.100 mm (0.0024 — 0.0039 in)
Drive pinion shim
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
32295AA0310.150
(0.0059) 32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069) 32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079) 32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089) 32295AA1010.500
(0.0197)
Main shaft rear plate
Dimension “A” mm (in) Part No. Mark
4.00 — 4.13
(0.1575 — 0.1626) 32294AA041 1
3.87 — 3.99
(0.1524 — 0.1571) 32294AA051 2
Snap ring (Outer-19)
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
Dimension “D” mm (in) Number of shim
52.50 — 53.11
(2.0669 — 2.0909)—
52.00 — 52.49
(2.0472 — 2.0665)1
51.26 — 51.99
(2.0181 — 2.0468)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)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
Snap ring (Inner-68)
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
Snap ring (Outer-25)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)

5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH)
wall clearance :
6.0 — 7.5 mm (0.236 — 0.295 in)
After installing a suitable reverse shifter lever, ad-
just the clearance using washers.
Reverse idler gear to transmission case wall
clearance:
0 — 0.5 mm (0 — 0.020 in)
8. SHIFTER FORK AND ROD
Select the suitable shifter forks so that both cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance :
A: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
B: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
9. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Reverse check plate adjustment
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall
Washer (20.5×26×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059) — —
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3 Approach to 2nd gear
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3 Approach to 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA211 No mark Standard
32812AA221 9Become distant from
5th gear by 0.2 mm
(0.008 in)
5th shifter fork (Turbo)
Part No. Mark Remarks
32812AA231 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in)
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA130 SNeutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 UNeutral position is
closer to reverse gear.
Reverse check plate
Par t No. Mar kAngle
θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.

5MT-5
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
10.EXTENSION ASSEMBLY
Thrust washer (50×61×t) to taper roller bearing
table outer race side clearance :
0.2 — 0.3 mm (0.0008 — 0.012 in)
NOTE:
Be sure to set within the standard clearance.
Thrust washer to center differential side
clearance :
0.15 — 0.35 mm (0.0059 — 0.0138 in)
11.FRONT DIFFERENTIAL
Bevel gear to pinion backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
12.TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clear-
ance :
0.01 — 0.15 mm (0.0004 — 0.0059 in)
Thrust washer (50×61×t)
Part No. Thickness mm (in)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
Washer (38.1×50×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
8030380210.925 —
0.950
(0.0364 —
0.0374)8030380231.025 —
1.050
(0.0404 —
0.0413)
8030380220.975 —
1.000
(0.0384 —
0.0394)——
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)

5MT-6
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
B: COMPONENT
1. TRANSMISSION CASE
MT-00002
T(3) (1)
(2)
(4) (5)
(12) (10) (11)
(18)
(13)
(9)
(8)
(7)
(6)
(16) (14)
(15)(17)

5MT-7
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
 Transmission case tightening torque
(1) Transmission case ASSY (Single-
range)(9) Oil seal (16) High-low cable bracket A (Dual-
range)
(10) Clamp
(2) Gasket (11) Pitching stopper bracket (17) High-low cable bracket B (Dual-
range)
(3) Drain plug (12) Clip
(4) Snap ring (Outer) (13) Oil level gauge (Non-turbo model) (18) Oil level gauge (Turbo model)
(5) Speedometer driven gear (14) Oil seal (Dual-range)
(6) Washer (15) Transmission case ASSY (Dual-
range)Tightening torque: N·m (kgf-m, ft-lb)
(7) Speedometer shaftT: 44 (4.5, 32.5) (Aluminum gasket)
(8) Snap ring (Outer)70 (7.1, 51.6) (Copper gasket)
Bolt No. Bolt sizeTightening torque:
N·m (kgf-m, ft-lb)
<5> to <15> 8 mm 25 (2.5, 18.1)
<1> to <4>
<16>, <17> 10 mm 39 (4.0, 28.9)
MT-00003

5MT-8
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. DRIVE PINION ASSEMBLY
(1) Drive pinion shaft (14) 1st driven gear (28) Lock washer
(2) Roller bearing (15) Baulk ring (29) Lock nut
(3) Washer (16) 1st-2nd synchronizer hub (30) Washer
(4) Thrust bearing (17) Insert key (31) Thrust bearing
(5) Needle bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(6) Driven shaft (19) Outer baulk ring (33) Washer
(7) Key (20) Synchro cone (34) Lock washer
(8) Woodruff key (21) Inner baulk ring (35) Lock nut
(9) Drive pinion collar (22) 2nd driven gear
(10) Needle bearing (23) 2nd driven gear bushTightening torque: N·m (kgf-m, ft-lb)
(11) Snap ring (Outer) (Non-turbo
model)(24) 3rd-4th driven gearT1: 30 (3.1, 22.1)
(25) Driven pinion shimT2: 120 (12.2, 88.5)
(12) Washer (Non-turbo model) (26) Roller bearingT3: 260 (26.5, 192)
(13) Sub gear (Non-turbo model) (27) 5th driven gear
MT-00004
(5)
(4)
(1)
(25)(26)(27) (28)(29)
(21)(22)(23)
(31)(30)(32)(33)(34) (24)
(20)(18)
(19)(6)(3)
(2)
(12) (11)
(10)
(9) (8)
(7)
(13)(16)(17)
(14)(15)
T1
T3
(35)T2
(30)

5MT-9
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. MAIN SHAFT ASSEMBLY (SINGLE RANGE)
(1) Oil seal (15) Needle bearing (28) Rev synchro cone
(2) Needle bearing (16) 4th gear thrust washer (29) Ball bearing
(3) Transmission main shaft (17) Double taper roller bearing (30) Synchro cone stopper
(4) Needle bearing (18) 5th gear thrust washer (Non-turbo
model)(31) Snap ring
(5) 3rd drive gear (32) Lock washer
(6) Inner baulk ring (19) 5th needle bearing race (33) Lock nut
(7) 3rd synchro cone (20) Needle bearing (34) Reverse idler gear shaft
(8) Outer baulk ring (21) Main shaft rear plate (35) Straight pin
(9) 3rd-4th coupling sleeve (22) 5th drive gear (36) Reverse idler gear
(10) 3rd-4th synchronizer hub (23) 5th baulk ring (37) Washer
(11) 3rd-4th shifting insert key (24) 5th-Rev shifting insert key
(12) 4th baulk ring (25) 5th-Rev synchronizer hubTightening torque: N·m (kgf-m, ft-lb)
(13) 4th drive gear (26) 5th-Rev coupling sleeveT: 120 (12.2, 88.5)
(14) 4th needle bearing race (27) Rev baulk ring
T
(18)
(19)(20)(21)(22)(23) (24)
(25)(26)(27)(28)(29)(30)(31)(32)(33)
(35)(34)(36)
(37)
(3)
(9)(10)
(4)(5) (2)
(1)
(6)(7)(8)(11)(17)
(12)(13)(14)(15)(16)
MT-00005

5MT-10
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
4. MAIN SHAFT ASSEMBLY (DUAL RANGE)
MT-01014
(3) (4)(4)
T2
T3
T1
T4
(5)
(2)
(1)(6)(6)
(7)
(8)
(9)(10)
(11)(17)(18)(19)(20)
(21)(22)
(23)(30)(31)(32)(33)
(34)(34)
(35)(35)
(37)(36)
(49)(50)(51)(52)(53)(54) (55)
(56)(57)(58)(59)(60)(61)(62)(63)(64)
(66) (69)
(70)
(71)(72)
(73)
(74)
(75)
(76)(77)(78)
(79)
(80)
(65)(67)(68) (38)(40)
(39)(40)(41)(42)(43)(44)(45)(46)(47)(48) (29) (12)(13) (14)
(15) (16)
(28)
(27) (26)
(25)
(24)(24)