2004 SUBARU FORESTER transmission

5MT-54
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
12.Transfer Drive 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 extension case assembly.
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
26 N·m (2.7 kgf-m, 20 ft-lb)
2) Install the transfer driven gear.
3) Install the extension case assembly.
4) Install the transfer case and extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>6) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring.
2) Remove the ball bearing.
D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
install to drive shaft.
ST 398177700 INSTALLER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
2) Install the snap ring on transfer drive shaft.
3) Check the clearance between snap ring and ball
bearing. Drive Gear.>
MT-00133
MT-00133
MT-00135
MT-00136
MT-00137
ST

5MT-55
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Drive Gear
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
 Broken or rusty bearings
 Worn or damaged
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
2) Drive gear
Replace the drive gear in the following cases:
 If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
If the measurement is not within specification, se-
lect a suitable snap ring.
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-00138

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

5MT-56
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Driven Gear
13.Transfer Driven 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 extension case assembly.
5) Remove the transfer driven gear.
6) Remove the bearing outer race from extension
case and transfer case.
B: INSTALLATION
1) Install the bearing outer race to extension case
and transfer case.
2) Install the transfer driven gear.
3) Install the transfer case and extension case as-
sembly. fer Case and Extension Case Assembly.>
4) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
5) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
(A) Bearing outer race (transfer case)
(B) Bearing outer race (extension case)
MT-00118
MT-00140 (B)
(A)
(A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension case
(C)
(A)
(D)(B)
MT-00141
MT-00118

5MT-57
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Driven Gear
C: DISASSEMBLY
1) Using the ST, remove the roller bearing (exten-
sion case side).
ST 498077000 REMOVER
2) Using the ST1 and ST2, remove the roller bear-
ing (transfer case side).
ST1 498077000 REMOVER
ST2 899864100 REMOVER
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension
case side).
ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
2) Using the ST, install the roller bearing (transfer
case side).
ST 499757002 INSTALLER
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton)
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
 Broken or rusty bearings
 Worn or damaged
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
2) Driven gear
Replace the drive gear in the following cases:
 If their tooth surfaces and shaft are excessively
broken or damaged.
(A) Roller bearing
(A) Roller bearing
MT-00143
(A)ST
MT-00144
(A)
ST1
ST2
(A) Roller bearing
(A) Roller bearing
MT-00145
(A)ST1
ST2
(A)
MT-00146
ST

5MT-58
MANUAL TRANSMISSION AND DIFFERENTIAL
Center Differential
14.Center Differential
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
3) Remove the extension case assembly. 5MT-50, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. 56, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. 5MT-50, INSTALLATION, Transfer Case and Ex-
tension Case Assembly.>
4) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
6) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
2) Do not disassemble the center differential ex-
cept ball bearing part because it is a non-disassem-
ble part.
D: ASSEMBLY
Install the ball bearing to center differential assem-
bly.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
 Broken or rusty bearings
 Worn or damaged
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
 Bearings having other defects
2) Center differential
Replace the center differential assembly in the fol-
lowing case:
 Worn or damaged
MT-00147
ST
(A) Ball bearing
MT-00148 (A)

5MT-59
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Check Sleeve
15.Reverse Check Sleeve
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring
and reverse check ball.
5) Remove the reverse check sleeve.
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
2) Install the reverse check ball, reverse accent
spring, gasket and plug to transfer case.
Tightening torque:
9.75 N·m (1.0 kgf-m, 7.2 ft-lb)
3) Install the shifter arm to transfer case assembly.
4) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
MT-00149
MT-00150
MT-00150
MT-00149

5MT-60
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Check Sleeve
C: DISASSEMBLY
1) Cover the reverse check sleeve with a rag, and
remove the snap ring using a screwdriver.
NOTE:
Replace the snap ring with a new one if deformed
or reactive force is weakened.
2) Remove the reverse check plate, reverse check
spring, reverse check cam, return spring (5th-Rev),
reverse accent shaft, return spring cap and return
spring (1st-2nd).
3) Remove the O-ring.
NOTE:
 Reverse check sleeve assembly uses an O-ring
which should not be scratched.
 Be careful not to break the adjustment shim
placed between reverse check sleeve assembly
and case.
D: ASSEMBLY
1) Install the return spring (1st-2nd), return spring
cap, reverse accent shaft, check cam, return spring
and check spring onto reverse check sleeve.
NOTE:
Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
2) Hook the bent section of reverse check spring
over reverse check plate.
3) Rotate the cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With the cam held in that position, install the
plate onto reverse check sleeve and hold with snap
ring.
5) Position a new O-ring in groove in sleeve.
(A) Snap ring
(A) Reverse check plate
(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
MT-00153
(A)
MT-00154
(B)(C)
(D)(E)
(F)(G) (A)
(A) Reverse check plate
(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
MT-00154
(B)(C)
(D)(E)
(F)(G) (A)