Subaru 2001 Forester User manual

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, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance 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 genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
G8050GE4

MANUAL TRANSMISSION AND
DIFFERENTIAL MT
Page
1. General Description.....................................................................................2
2. Transmission Gear Oil ..............................................................................31
3. Manual Transmission Assembly................................................................32
4. Transmission Mounting System................................................................39
5. Oil Seal......................................................................................................41
6. Switches and Harness ..............................................................................42
7. Vehicle Speed Sensor...............................................................................44
8. Preparation for Overhaul...........................................................................45
9. Transfer Case and Extension Case Assembly .........................................46
10. Oil Pump....................................................................................................50
11. Transfer Drive Gear ..................................................................................52
12. Transfer Driven Gear ................................................................................54
13. Center Differential .....................................................................................56
14. Reverse Check Sleeve..............................................................................57
15. Transmission Case....................................................................................60
16. Main Shaft Assembly for Single-Range....................................................67
17. Main Shaft Assembly for Dual-Range.......................................................73
18. Input Shaft Assembly ................................................................................79
19. Drive Pinion Shaft Assembly.....................................................................83
20. Front Differential Assembly.......................................................................92
21. Speedometer Gear....................................................................................98
22. Reverse Idler Gear....................................................................................99
23. Shifter Fork and Rod...............................................................................101
24. Counter Gear...........................................................................................104
25. General Diagnostic..................................................................................106

1. General Description S503001
A: SPECIFICATIONS S503001E49
1. MANUAL TRANSMISSION AND DIFFERENTIAL S503001E4901
Model Non-Turbo Turbo Without oil pump With oil pump
Dual-range Single-range
Type 5×2-forward speeds
and 1 ×2-reverse 5-forward speeds and 1-reverse
Transmission gear ratio
1st 3.454 3.454
2nd 2.062 1.947
3rd 1.448 1.366
4th 1.088 0.972
5th 0.871 0.738
Reverse 3.333
Auxiliary transmission gear
ratio High 1.000 —
Low 1.447 —
Front reduction
gear Final Type of gear Hypoid
Gear ratio 4.111 4.444
Rear reduction
gear
Transfer Type of gear Helical
Gear ratio 1.000 1.081
Final Type of gear Hypoid
Gear ratio 4.111 4.444 4.111
Front differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differen-
tial Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission gear oil capacity 4.0 (4.2 US qt, 3.5
Imp qt) 3.5 (3.7 US qt, 3.11 Imp qt) 4.4 (4.7 US qt, 3.9 Imp qt)
2. TRANSMISSION GEAR OIL S503001E4902
Recommended oil
B1H0024
3. TRANSMISSION CASE ASSEMBLY
S503001E4903
Drive pinion shim adjustment
Hypoid gear backlash
0.13 —0.18 mm (0.0051 —0.0071 in)
Drive pinion shim
Part No. Thickness
mm (in) Part No. Thickness
mm (in)
32295AA031 0.150
(0.0059) 32295AA071 0.250 (0.0098)
32295AA041 0.175
(0.0069) 32295AA081 0.275 (0.0108)
32295AA051 0.200
(0.0079) 32295AA091 0.300 (0.0118)
32295AA061 0.225
(0.0089) 32295AA101 0.500 (0.0197)
MT-2
GENERAL DESCRIPTION
Manual Transmission and Differential

Selection of main shaft rear plate
Main shaft rear plate
Dimension “A”mm
(in) Part No. Mark
4.00 —4.13
(0.1575 —0.1626) 32294AA041 1
3.87 —3.99
(0.1524 —0.1571) 32294AA051 2
Snap ring to counter washer clearance
0.05 —0.35 mm (0.0020 —0.0138 in)
Snap ring (Outer-19)
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
Input shaft holder adjustment
Dimension “D”mm (in) Number of shim
52.50 —53.11
(2.0669 —2.0909) —
52.00 —52.49
(2.0472 —2.0665) 1
51.26 —51.99
(2.0181 —2.0468) 2
4. DRIVE PINION ASSEMBLY S503001E4904
Preload adjustment of thrust bearing
Starting torque
0.3 —0.8 N·m (0.03 —0.08 kgf-m, 0.2 —0.6
ft-lb)
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)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
5. INPUT SHAFT ASSEMBLY S503001E4910
Snap ring (Outer-28) to ball bearing clearance
0—0.12 mm (0 —0.0047 in)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
Snap ring (Inner-68) to bearing clearance
0—0.12 mm (0 —0.0047 in)
Snap ring (Inner-68)
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
6. MAIN SHAFT S503001E4911
Snap ring (Outer-25) to synchronizer hub clearance
0.060 —0.100 mm (0.0024 —0.0039 in)
Snap ring (Outer-25)
Part No. Thickness
mm (in) Part No. Thickness
mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)
7. REVERSE IDLER GEAR S503001E4905
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall
clearance
6.0 —7.5 mm (0.236 —0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case
wall
After installing a suitable reverse shifter lever,
adjust reverse idler gear to transmission case wall
clearance to within 0 to 0.5 mm (0 to 0.020 in)
using washers.
Washer (20.5 ×26 ×t)
Part No. Thickness
mm (in) Part No. Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059) ——
MT-3
GENERAL DESCRIPTION Manual Transmission and Differential

8. SHIFTER FORK AND ROD S503001E4906
Select suitable shifter forks so that both coupling
sleeve and reverse driven gear are positioned in
the center of their synchromesh mechanisms.
Rod end clearance
A: 1st-2nd —3rd-4th
0.4 —1.4 mm (0.016 —0.055 in)
B: 3rd-4th —5th
0.5 —1.3 mm (0.020 —0.051 in)
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1 Approach to 1st gear
by 0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3 Approach to 2nd gear
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1 Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3 Approach to 3rd gear
by 0.2 mm (0.008 in)
Non-Turbo model
5th shifter fork
Part No. Mark Remarks
32812AA201 4 Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA211 5 Standard
32812AA221 6 Become distant from 5th gear by 0.2 mm
(0.008 in)
Turbo model
5th shifter fork
Part No. Mark Remarks
32812AA231 7 Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
32812AA251 9 Become distant from 5th gear by 0.2 mm
(0.008 in)
9. TRANSFER CASE S503001E4907
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA090 3 Neutral position is
closer to 1st.
32188AA100 0 Standard
32188AA110 1 Neutral position is
closer to reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark Angle θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
MT-4
GENERAL DESCRIPTION
Manual Transmission and Differential

10. EXTENSION ASSEMBLY S503001E4908
Thrust washer (50 ×61 ×t) to taper roller bearing
table outer race side clearance
0.2 —0.3 mm T (0.0008 —0.012 in T)
NOTE:
T: Tight
Thrust washer (50 ×61 ×t)
Part No. Thickness mm (in)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
Thrust washer to center differential side clearance
0.15 —0.35 mm (0.0059 —0.0138 in)
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
11. FRONT DIFFERENTIAL S503001E4909
Bevel gear to pinion backlash
0.13 —0.18 mm (0.0051 —0.0071 in)
Washer (38.1 ×50 ×t)
Part No. Thickness
mm (in) Part No. Thickness mm (in)
803038021
0.925 —
0.950
(0.0364 —
0.0374)
803038023
1.025 —
1.050
(0.0404 —
0.0413)
803038022
0.975 —
1.000
(0.0384 —
0.0394)
——
Pinion shaft to axle drive shaft clearance
0—0.2 mm (0 —0.008 in)
Snap ring (Outer-28)
Part No. Thickness
mm (in) Part No. Thickness mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
MT-5
GENERAL DESCRIPTION Manual Transmission and Differential

B: COMPONENT S503001A05
1. TRANSMISSION CASE S503001A0501
S3M0616A
MT-6
GENERAL DESCRIPTION
Manual Transmission and Differential

(1) Transmission case ASSY (Turbo
model)
(2) Gasket
(3) Drain plug
(4) Snap ring (Outer)
(5) Speedometer driven gear
(6) Washer
(7) Speedometer shaft
(8) Snap ring (Outer)
(9) Oil seal
(10) Clamp
(11) Pitching stopper bracket
(12) Clip
(13) Oil level gauge (Non-turbo
model)
(14) Oil seal (Non-turbo model)
(15) Transmission case ASSY (Non-
turbo model)
(16) High-low cable bracket A (Non-
turbo model)
(17) High-low cable bracket B (Non-
turbo model)
(18) Oil level gauge (Turbo model)
(19) Inlet pipe (with oil pump)
Tightening torque: N·m (kgf-m, ft-lb)
T: 44 (4.5, 32.5)
Size All models Tightening torque: N·m (kgf-m, ft-lb)
8 mm bolt <5> —<15> 25 (2.5, 18.1)
10 mm bolt <1> —<4>
<16> —<17> 39 (4.0, 28.9)
MT-7
GENERAL DESCRIPTION Manual Transmission and Differential

2. DRIVE PINION ASSEMBLY S503001A0502
S3M0423B
(1) Drive pinion shaft
(2) Roller bearing
(3) Washer
(4) Thrust bearing
(5) Needle bearing
(6) Driven shaft
(7) Key
(8) Woodruff key
(9) Drive pinion collar
(10) Needle bearing
(11) Snap ring (Outer)
(12) Washer
(13) Sub gear
(14) 1st driven gear
(15) Baulk ring
(16) 1st-2nd synchronizer hub
(17) Insert key
(18) Reverse driven gear
(19) Outer baulk ring
(20) Synchro cone
(21) Inner baulk ring
(22) 2nd driven gear
(23) 2nd driven gear bush
(24) 3rd-4th driven gear
(25) Driven pinion shim
(26) Roller bearing
(27) 5th driven gear
(28) Lock washer
(29) Lock nut
(30) Washer
(31) Thrust bearing
(32) Differential bevel gear sleeve
(33) Washer
(34) Lock washer
(35) Lock nut
Tightening torque: N·m (kgf-m, ft-lb)
T1: 29 (3.0, 21.7)
T2: 118 (12.0, 86.8)
T3: 265 (27, 195)
MT-8
GENERAL DESCRIPTION
Manual Transmission and Differential

3. MAIN SHAFT ASSEMBLY S503001A0503
B3M2120B
(1) Oil seal
(2) Needle bearing
(3) Transmission main shaft
(4) Needle bearing
(5) 3rd drive gear
(6) Inner baulk ring (Turbo model)
(7) 3rd synchro cone (Turbo model)
(8) Outer baulk ring (Turbo model)
(9) 3rd-4th coupling sleeve
(10) 3rd-4th synchronizer hub
(11) 3rd-4th shifting insert key
(12) 4th baulk ring
(13) 4th drive gear
(14) 4th needle bearing race
(15) Needle bearing
(16) 4th gear thrust washer
(17) Ball bearing
(18) Baulk ring (Non–turbo model)
(19) 5th gear thrust washer
(20) 5th needle bearing race
(21) Needle bearing
(22) Main shaft rear plate
(23) 5th drive gear
(24) 5th baulk ring
(25) 5th-Rev shifting insert key
(26) 5th-Rev synchronizer hub
(27) 5th-Rev coupling sleeve
(28) Rev baulk ring
(29) Rev synchro cone
(30) Ball bearing
(31) Synchro cone stopper
(32) Snap ring
(33) Lock washer
(34) Lock nut
(35) Reverse idler gear shaft
(36) Straight pin
(37) Reverse idler gear
(38) Washer
Tightening torque: N·m (kgf-m, ft-lb)
T: 118 (12.0, 86.8)
MT-9
GENERAL DESCRIPTION Manual Transmission and Differential