2004 SUBARU FORESTER transmission

5MT-101
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
3. TOOTH CONTACT OF HYPOID GEAR
Check the tooth contact of hypoid gear as follows:
Apply a uniform thin coat of red lead on both tooth
surfaces of 3 or 4 teeth of the hypoid gear. Move
the hypoid gear back and forth by turning the trans-
mission main shaft until a definite contact pattern is
developed on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. ferential Assembly.>
 Tooth contact is correct.
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential. 96, REMOVAL, Front Differential Assembly.>
2) Select a different washer from the table and in-
stall.
3) Adjust until the specified value is obtained.
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
Adjust backlash by turning the holder in right side
case.
ST 499787000 WRENCH ASSY
NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.0020 in).
3. TOOTH CONTACT OF HYPOID GEAR
1) Adjust until the teeth contact is correct.
2) Check and adjust the teeth contact with following
table.
 Tooth contact
Checking item:Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
Washer
Part No. Thickness mm (in)
8030380210.925 — 0.950
(0.0364 — 0.0374)
8030380220.975 — 1.000
(0.0384 — 0.0394)
803038023 1.025 — 1.050
(0.0404 — 0.0413)
MT-00294
(A)
(B) (C)
(D)
(A) Toe side
(B) Heel side
MT-00176
ST
MT-00296
0.05mm(0.0020 in)
AT-00207
(A)
(B)

5MT-102
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
 Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to bring drive pinion
close to crown gear.
 Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting shim in order to move drive pin-
ion away from crown gear. Toe contact (Inside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting shim in order to bring drive pin-
ion close to crown gear.
 Heel contact (Outside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to move drive pinion
away from crown gear.
AT-00208
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212

5MT-103
MANUAL TRANSMISSION AND DIFFERENTIAL
Speedometer Gear
22.Speedometer 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 transmission case. 62, REMOVAL, Transmission Case.>
5) Remove the vehicle speed sensor. 5MT-46, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out speed-
ometer driven gear. Next, remove the oil seal,
speedometer shaft and washer.
B: INSTALLATION
1) Install the washer and speedometer shaft, and
press fit the new oil seal with ST.
ST 899824100 or 499827000PRESS
2) Install the vehicle speed sensor. 46, INSTALLATION, Vehicle Speed Sensor.>
3) Install the speedometer driven gear and new
snap ring.
4) Install the transmission case. INSTALLATION, Transmission Case.>
5) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
6) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
7) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
(A) Outer snap ring
(B) Speedometer driven gear
MT-00301
(A)(B)
(A) Outer snap ring
(B) Speedometer driven gear
MT-00301
(A)(B)

5MT-104
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
23.Reverse Idler 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 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) Remove the shifter forks and rods. 106, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the Rev
idler gear shaft, reverse idler gear and washer.
10) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse shifter lever, reverse idler
gear and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall. to 5MT-104, INSTALLATION, Reverse Idler Gear.>
and Idler Gear.>
3) Install the shifter forks and rods. 106, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. 96, INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
Single-Range model
sembly For Single-Range.>
Dual-Range model
sembly For Dual-Range.>
6) Install the drive pinion shaft assembly. 5MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
7) Install the transmission case. INSTALLATION, Transmission Case.>
8) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
9) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
10) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
(A) Straight pin
(B) Rev idler gear shaft
(C) Rev idler gear
(D) Washer
MT-00303
(A)(B)
(C)
(D)
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
MT-00304
(A)
(B)
(D)
(C)

5MT-105
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
C: INSPECTION
1) Move the reverse shifter rod toward the reverse
side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select the appropriate re-
verse shifter lever and adjust.
Clearance A:
6.0 — 7.5 mm (0.236 — 0.295 in)
2) After installing a suitable reverse shifter lever,
shift into neutral. Inspect the clearance between re-
verse idler gear and transmission case wall.
If out of specification, select the appropriate washer
and adjust.
Clearance:
0 — 0.5 mm (0 — 0.020 in)
3) Check the reverse idler gear and shaft for dam-
age. Replace if damaged.
D: ADJUSTMENT
1) Select the appropriate reverse shifter lever from
the table below, and adjust until the gap between
the reverse idler gear and transmission case wall is
within specification.
Clearance A:
6.0 — 7.5 mm (0.236 — 0.295 in)
2) Select the appropriate washer from the table be-
low, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.
Clearance:
0 — 0.5 mm (0 — 0.020 in)
MT-00305
A
MT-00306
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to case wall
Washer
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
MT-00305
A
MT-00306

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)

5MT-108
MANUAL TRANSMISSION AND DIFFERENTIAL
Shifter Fork and Rod
4) Inspect the clearance between 3rd, 4th drive
gear and coupling sleeve. If any clearance is not
within specifications, replace the shifter fork as re-
quired.
Clearance (a) and (b):
9.3 mm (0.366 in)
5) Inspect the clearance between 5th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in) 6) Inspect the rod end clearances (A) and (B). If
any clearance is not within specifications, replace
the rod or fork as required.
Clearance (A):
1st-2nd to 3rd-4th:
0.4 — 1.4 mm (0.016 — 0.055 in)
Clearance (B):
3rd-4th to 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
(A) 3rd drive gear
(B) Coupling sleeve
(C) 4th drive gear
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in).
32810AA071 — Standard
32810AA101 3Approach to 3rd gear
by 0.2 mm (0.008 in).
(A) 5th drive gear
(B) Coupling sleeve
MT-00940
(A)(B)
(C) (a) (b)
MT-00315
(A)(B) (a)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in).
32812AA211 — Standard
32812AA221 9Approach to 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 — Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in).
MT-00379
(B)(A)