2004 SUBARU FORESTER transmission

5MT-93
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
 Bearings whose balls, outer races and inner rac-
es are broken or rusty.
 Worn bearings
 Bearings that fail to turn smoothly or make noise
when turned after gear oil lubrication.
 The roller bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
 Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
 When the sliding surface is damaged or abnor-
mally worn.
 When the inner wall is abnormally worn.
3) Gears
 Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
 Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
 Correct or replace if the inner surface or end face
is damaged.4) Baulk ring
Replace the ring in the following cases:
 When the inner surface and end face are dam-
aged.
 When the ring inner surface is abnormally or par-
tially worn down.
 If the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 — 1.0 mm (0.020 — 0.040 in)
 When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
(A) Drive pinion shaft
(B) Roller bearing
MT-00264
(A)
(B)
MT-00265
(A)
MT-00208

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-96
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
21.Front Differential Assembly
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 transmission case. 62, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
Single-range model
For Single-Range.>
Dual-range model
For Dual-Range.>
6) Remove the differential assembly.
NOTE:
 Be careful not to confuse the right and left roller
bearing outer races.
 Be careful not to damage the retainer oil seal.
7) Remove the differential side retainers using ST.
ST 499787000 WRENCH ASSY
8) Remove the bearing outer race from transmis-
sion case.
ST 398527700 PULLER ASSY
B: INSTALLATION
1) Insert the bearing outer race to transmission
case.
NOTE:
Apply the transmission gear oil to outer surface of
bearing outer race.
2) Install the differential side retainers using ST.
ST 499787000 WRENCH ASSY
3) Install the differential assembly.
NOTE:
 Be careful not to fold the sealing lip of oil seal.
 Wrap the right and left spline sections of axle
shaft with vinyl tape to prevent scratches.
4) Install the main shaft assembly. 69, INSTALLATION, Main Shaft Assembly For Sin-
gle-Range.>
5) Install the drive pinion assembly. 69, INSTALLATION, Main Shaft Assembly For Sin-
gle-Range.>
6) Install the transmission case. INSTALLATION, Transmission Case.>
7) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
8) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
MT-00162
MT-00176
ST
MT-00162

5MT-97
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Loosen the twelve bolts and remove the hypoid
driven gear.
2) Drive out the straight pin from differential assem-
bly toward hypoid driven gear.
ST 899904100 REMOVER3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion and gear and washer.
4) Remove the roller bearing using ST.
ST 899524100 PULLER SET
(A) Hypoid driven gear
(A)
MT-00275
MT-00276
ST
(A) Pinion shaft
(B) Differential bevel pinion
(C) Differential bevel gear
(D) Washer
MT-00277
(A)
(D)
(D)
(C)
(C)
(B)
(B)
MT-00278
ST

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-99
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
4) Install the roller bearing to differential case.
CAUTION:
Do not apply load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
5) Install the hypoid driven gear to differential case
using twelve bolts.
Tightening torque:
T: 62 N·m (6.3 kgf-m, 45.6 ft-lb)2. SIDE RETAINER
1) Install a new oil seal.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
CAUTION:
 When pressing fit the oil seal to side retainer,
tap it to press fit using a plastic hammer.
 Do not use the press.
2) Install a new O-ring.
NOTE:
Do not stretch or damage the O-ring.
(A) Hypoid driven gear
(B) Differential case
MT-00287
ST1
ST2
MT-00288
(B) (A)T
MT-00289
ST
MT-00279

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