2004 SUBARU FORESTER manual transmission

5MT-27
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398527700 PULLER ASSY  Used for removing extension case roller bear-
ing.
 Used for removing front differential side
retainer bearing outer race.
 Used for removing front differential side
retainer oil seal.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
398177700 INSTALLER  Used for installing bearing cone of transfer
driven gear (transfer case side).
 Used for installing ball bearing of transfer drive
gear.
398507703 DUMMY COLLAR  Used for installing input shaft holder oil seal.
 For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398527700
ST-398643600
ST-398177700
ST-398507703

5MT-28
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398663600 PLIERS  Used for removing and installing input shaft
snap ring.
 For dual-range model.
499757001 SNAP RING GUIDE  Used for installing snap ring (OUT 25).
 For dual-range model.
899858600 RETAINER  Used for removing ball bearing.
 For dual-range model.
899474100 EXPANDER  Used for removing and installing snap ring.
 For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398663600
ST-499757001
ST-899858600
ST-899474100

5MT-29
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899580100 INSTALLER  Used when pressing ball bearings into input
shaft.
 For dual-range model.
399513600 INSTALLER  Used when pressing ball bearings into input
shaft.
 For dual-range model.
28399SA000 FRONT DRIVE
SHAFT REMOVERUsed for removing front drive shaft. (Commonly
used for MT model and AT model)
28399SA010 FRONT DRIVE
SHAFT OIL SEAL
PROTECTORUsed for protecting oil seal when installing front
drive shaft. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899580100
ST-399513600
ST28399SA000
ST28399SA010

5MT-30
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. GENERAL TOOL
18675AA000 DIFFERENTIAL
SIDE OIL SEAL
INSTALLERUsed for installing differential side retainer oil
seal.
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18675AA000

5MT-31
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Gear Oil
2. Transmission Gear Oil
A: INSPECTION
1) Park the vehicle on a level surface.
2) Turn the ignition switch to OFF, and wait until the
engine cools.
3) Remove the oil level gauge and wipe it clean.
4) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper direction.
5) Pull out the oil level gauge again and check the
oil level on it. If it is below the lower level, add oil
through the oil level gauge hole to bring the level up
to the upper level.
B: REPLACEMENT
1) Pull out the oil level gauge.
2) Lift-up the vehicle.
3) Drain the transmission gear oil completely.
CAUTION:
 Directly after the engine has been running,
the transmission gear oil is hot. Be careful not
to burn yourself.
 Be sure not to spill the transmission gear oil
on exhaust pipe to prevent it from emitting
smoke or firing. When the transmission gear oil
is split on exhaust pipe, wipe it away complete-
ly.4) Tighten the transmission gear oil drain plug us-
ing a new gasket.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-
ket)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
5) Lower the vehicle.
6) Pour gear oil into the gauge hole.
Recommended gear oil:
Use GL-5 (75 W — 90) or equivalent.
Gear oil capacity:
Single-range model;
Model without oil pump
3.52 (3.7 US qt, 3.1 Imp qt)
Model with oil pump
3.92 (4.1 US qt, 3.4 Imp qt)
Dual-range model;
4.02 (4.2 US qt, 3.5 Imp qt)
7) Measure the level of transmission gear oil, and
then check the level within the specified range.
CAUTION:
When inserting the level gauge into transmis-
sion gear, align the protrusion on the side of
the top part of level gauge with the notch in the
gauge hole.
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C) (A)
(A) Drain plug
(B) Gasket
MT-00061
(A) (B)

5MT-32
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
3. Manual Transmission As-
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Drain the transmission gear oil completely. to 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
4) Open the front hood fully, and support with stay.
5) Remove the air intake duct and air cleaner case.
(Non-turbo model) AL, Air Intake Duct.> MOVAL, Air Cleaner Case.>
6) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the intercooler. (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>
8) Disconnect the following connectors and trans-
mission cable.
(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
 Non-turbo model Turbo model
(4) Vehicle speed sensor
9) Remove the snap pin and pin from drive select
cable.
10) Remove the drive select cable on transmission.
(Dual-range model)
11) Remove the starter. MOVAL, Starter.>
ME-00062
MT-00063
(A) Snap pin
(B) Clevis pin
(C) Drive select cable
MT-00064
MT-00065
MT-00066
(A)
(B)
(C)

5MT-33
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
12) Remove the operating cylinder from transmis-
sion, and then hang it with wires.
 Non-turbo model
 Turbo model
13) Remove the pitching stopper.
14) Set the ST.
ST 41099AA020 ENGINE SUPPORT ASSY15) Separate the clutch release fork from release
bearing. (Turbo model)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using 10 mm hexagon
wrench.
(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.
(4) Raise the release fork and unfasten the re-
lease bearing tabs to free release fork.
NOTE:
Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
MT-00067
MT-00068
AT-00023
MT-00070
ST(A) Release fork shaft
(B) Bolt (6 mm)
MT-00071
MT-00072 (B)(A)

5MT-34
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
16) Remove the bolts which holds right upper side
of transmission to engine.
17) Remove the front and center exhaust pipes.
(Non-turbo model) AL, Front Exhaust Pipe.>
18) Remove the center exhaust pipe. (Turbo mod-
el). Exhaust Pipe.>
19) Remove the rear exhaust pipe and muffler.
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
20) Remove the heat shield cover. (Non-turbo
model)
21) Remove the hanger bracket from right side of
transmission.
22) Remove the propeller shaft. REMOVAL, Propeller Shaft.>23) Remove the gear shift rod and stay from trans-
mission.
(1) Disconnect the stay from transmission.
(2) Disconnect the gear shift rod from transmis-
sion.
24) Disconnect the ATF cooler hose from transmis-
sion side oil cooler pipe. (Model with oil pump)
25) Disconnect the stabilizer link from transverse
link.
26) Remove the bolts securing ball joint of trans-
verse link to housing, and then separate the trans-
verse link and housing.
MT-00073
MT-00074
(A) Stay
(B) Gear shift rod
MT-00075
(A)
(B)
(B)
FS-00026