2004 SUBARU FORESTER 5MT-32

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-50
MANUAL TRANSMISSION AND DIFFERENTIAL
Transfer Case and Extension Case Assembly
11.Transfer Case and Extension
Case Assembly
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.
4) Remove the shifter arm.
5) Remove the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.2) Remove the bearing outer race from extension
case.
3) While pressing the bearing outer race horizontal-
ly, turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
5) Measure the depth “X”.
NOTE:
Measure with bearing cone and thrust washer re-
moved.
6) Calculate the space “t” using the following equa-
tion: t = X−W+0.2 to 0.3 mm (0.008 to 0.012 in)
7) Select the nearest washer in the following table:
Standard clearance between thrust washer and
taper roller bearing:
0.2 — 0.3 mm (0.008 — 0.012 in)
NOTE:
Set the clearance within standard clearance.
MT-00116
MT-00117
MT-00118
(A) Bearing outer race
(B) Extension case
MT-00119
(B)
(A)
MT-00120
W
MT-00121
X

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-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-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-62
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
16.Transmission Case
A: REMOVAL
1. SINGLE-RANGE
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the clutch release lever. 20, REMOVAL, Release Bearing and Lever.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
4) Remove the bearing mounting bolts.
5) Remove the main shaft rear plate.
6) Separate the transmission case into right and
left cases by loosening the coupling bolts and nuts.7) Remove the drive pinion shaft assembly from left
side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
8) 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.
2. DUAL-RANGE
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the clutch release lever. 20, REMOVAL, Release Bearing and Lever.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>(A) Main shaft rear plate
MT-00158
MT-00159
(A)
MT-00160
(A) Main shaft assembly
(B) Drive pinion shaft assembly
MT-00161
(A)
(B)
MT-00162

5MT-69
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
17.Main Shaft Assembly For Sin-
gle-Range
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. 50, REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
B: INSTALLATION
1) Wrap the clutch splined section with vinyl tape to
prevent damage to oil seal.
2) Apply grease Unilube #2 (or equivalent) to the
sealing lip of oil seal.
3) Install the needle bearing and new oil seal onto
the front of transmission main shaft assembly.
4) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
5) Install the drive pinion assembly. 87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
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.>
C: DISASSEMBLY
1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
NOTE:
Unlock the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3) Remove the 5th-Rev sleeve and hub assembly,
5th baulk ring, 5th drive gear and needle bearing.
4) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
MT-00185
(A)
(A) 5th-Rev sleeve and hub ASSY
(B) 5th baulk ring
(C) 5th drive gear
(A) Synchro cone stopper
(B) Snap ring
MT-00186ST2ST1
MT-00187
(A) (B) (C)
MT-00188
(A) (B)