2004 SUBARU FORESTER transmission

5MT-109
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
25.Counter Gear
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) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.
5) Slide the washer at rear of high-low counter
shaft, and remove the straight pin from counter
shaft.6) Remove the counter shaft from transmission
case, taking care not to drop the counter gear and
two washers.
NOTE:
 Be careful not to damage the O-ring.
 Be careful not to drop the straight pin on front
side.
 Be careful not to drop the two needle bearings
and collar contained in counter gear.
B: INSTALLATION
1) Install the O-ring and straight pin onto counter
gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
 Counter gear shaft
 Two counter gear washers
 Two needle bearings
 Counter gear collar
 Counter gear
 Straight pin
 Snap ring
3) Install the transmission case. INSTALLATION, Transmission Case.>
4) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
5) Install the manual transmission assembly on ve-
hicle. Transmission Assembly.>
NOTE:
 Make sure that the cut-out end surface of counter
gear shaft does not protrude above the end surface
of the case.
 Position the cut-out portion of counter gear shaft
as shown in the figure.(A) Snap ring
(A) Straight pin
(B) Counter gear
MT-00317
(A)
MT-00318(A)
(B)
(A) Counter shaft
(B) Counter gear
(C) Washers
MT-00319
(A)
(B)(C)

5MT-110
MANUAL TRANSMISSION AND DIFFERENTIAL
Counter Gear
C: INSPECTION
1) After installing the snap ring, measure the clear-
ance between snap ring and counter washer.
Clearance:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
2) If the clearance is out of measured value, select
a snap ring and install to put clearance within mea-
sured value. Counter Gear.>
D: ADJUSTMENT
Selection of snap ring:
If the measurement is not within specification, se-
lect suitable snap ring.
Snap ring
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)

5MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
26.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
N
OTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gearReplace.
(b) Worn, damaged or burred chamfer of
spline of gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wear Correct or replace.
2. Gear slips out.
 Gear slips out when coasting on rough
road.
 Gear slips out during acceleration.(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail springReplace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeveReplace.
(f) Worn tooth step of synchronizer hub Replace.
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and 2nd bush Replace.
(i) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis-
sion.
N
OTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.Replace.

5MT-112
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
2. DIFFERENTIAL
Symptom Possible cause Remedy
1. Broken differential (case, gear, bear-
ing, etc.)
N
OTE:
Noise will develop and finally it will be-
come impossible to continue to run due to
broken pieces obstructing the gear revo-
lution. (a) Insufficient or improper oil Disassemble the differential and replace
broken components and at the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutch Readjust the bearing preload and back-
lash and face contact of gears.
(c) Improper adjustment of taper roller
bearingAdjust.
(d) Improper adjustment of drive pinion
and hypoid driven gear Adjust.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions. Add recommended oil to specified level.
Do not use the vehicle under severe oper-
ating conditions.
(f) Loose hypoid driven gear clamping
boltsTighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas, bear-
ing, body, etc. are easily mistaken for the
differential noise. Pay special attention to
the hypoid gear noise because it is easily
confused with other gear noises. There
are the following four kinds of noises.
 Gear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
 Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
 Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
 Noise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc. (a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinionReplace as a set.
Readjust the bearing preload.
(d) Loose roller bearing Readjust the hypoid driven gear to drive
pinion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential caseReplace.
(f) Worn washer and differential pinion
shaftReplace.

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

CL-16
CLUTCH SYSTEM
Clutch Disc and Cover
2. Clutch Disc and Cover
A: REMOVAL
1) Remove the transmission assembly from vehicle
body. mission Assembly.>
2) Install the ST on flywheel.
ST 499747100 CRANKSHAFT STOPPER
3) Remove the clutch cover and clutch disc.
NOTE:
 Take care not to allow oil on the clutch disc fac-
ing.
 Do not disassemble either the clutch cover or
clutch disc.
B: INSTALLATION
1) Insert the ST into clutch disc and install them on
the flywheel by inserting the ST end into pilot bear-
ing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST 499747100 CLUTCH DISC GUIDE2) Position “0” marks on clutch cover and flywheel
120° apart, and then tighten the clutch cover instal-
lation bolts diagonally.
NOTE:
 “0” marks indicate the directions of residual un-
balance.
 Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
(A) Clutch cover
(A) Flywheel side
CL-00011
(A)
ST
CL-00012
(A)
ST
(A) “0” marks
CL-00013 (A)ST(2)
(5)
(3)(1)
(6)
(4)

CL-17
CLUTCH SYSTEM
Clutch Disc and Cover
C: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of
facing. Replace if facings are worn locally or worn
down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any cleaning fluid.
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace the clutch disc and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other points for oil
leakage.4) Run out on facing
If run out exceeds the specified value at the outer
circumference of facing, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
Limit for run out:
2.0 L Non-Turbo model and LHD 2.5 L Non-
Turbo model:
0.8 (0.031 in) mm at R = 110 mm (4.33 in)
Turbo model and RHD 2.5 L Non-Turbo mod-
el:
1.0 (0.039 in) mm at R = 110 mm (4.33 in)
5) Worn spline, loose rivets and torsion spring fail-
ure.
Replace defective parts.
(A) Clutch facing
CL-00014
CL-00015
(A)
(A) Spline
(B) Rivet
(C) Torsion spring
CL-00016
ST
CL-00017

CL-19
CLUTCH SYSTEM
Flywheel
3. Flywheel
A: REMOVAL
1) Remove the transmission assembly. 5MT-32, REMOVAL, Manual Transmission As-
sembly.>
2) Remove the clutch cover and clutch disc. to CL-16, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
B: INSTALLATION
1) Install the flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER2) Tighten the flywheel attaching bolts to the spec-
ified torque.
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
3) Install the clutch disc and cover. INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace the flywheel.
2) Smoothness of rotation
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
(A) Flywheel
CL-00019ST (A)
CL-00020ST
(A) Flywheel
(B) Ring gear
CL-00021
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
CL-00022
(B)
(A)