Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 2004 3 - Transmission Manual and Differential Main Shaft Assembly (Single-Range)
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MAIN SHAFT ASSEMBLY (SINGLE-RANGE)
MANUAL TRANSMISSION AND DIFFERENTIAL
16.Main Shaft Assembly (Single- C: DISASSEMBLY
Range) 1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
A: REMOVAL seal and needle bearing by hand.
1) Remove the manual transmission assembly 2) Remove the lock nut from transmission main
from vehicle. NOTE:
2) Remove the transfer case with extension case Remove the caulking before removing lock nut.
assembly.
ST2 499987003 SOCKET WRENCH (35)
3) Remove the transmission case.
4) Remove the drive pinion shaft assembly.
5) Remove the main shaft assembly.
B: INSTALLATION
1) Wrap the clutch splined section with vinyl tape to
prevent damage to oil seal. ST2 ST1
MT-00186
2) Apply grease (Unilube #2 or equivalent) to the
sealing lip of oil seal. 3) Remove the 5th-Rev sleeve and hub assembly,
3) Install the needle bearing and new oil seal onto 5th baulk ring, 5th drive gear and needle bearing.
the front of transmission main shaft assembly.
4) Install the needle bearing outer race knock pin (C)
(B)
hole into transmission case knock pin. (A)
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
MT-00187
(A) 5th-Rev sleeve and hub ASSY
(B) 5th baulk ring
(C) 5th drive gear
(A)
4) Remove the snap ring and synchro cone stopper
MT-00185 from 5th-Rev sleeve and hub assembly.
5) Install the drive pinion assembly.
(A)
6) Install the transmission case.
7) Install the transfer case with extension case as-
sembly.
8) Install the manual transmission assembly to ve-
hicle.
(A) Synchro cone stopper
(B) Snap ring
5MT-57
MAIN SHAFT ASSEMBLY (SINGLE-RANGE)
MANUAL TRANSMISSION AND DIFFERENTIAL
5) Using the ST1, ST2 and a press, remove the ball 6) Using the ST1 and ST2, remove rest of the
bearing, synchro cone and baulk ring (Rev). parts.
NOTE: NOTE:
Replace the sleeve and hub with new ones. Do not Replace the sleeve and hub with new ones. Do not
attempt to disassemble because they must engage attempt to disassemble because they must engage
at a specified point. If they should be disassem- at a specified point. If they should be disassem-
bled, mark engagement point on splines before- bled, mark engagement point on splines before-
hand. hand.
ST1 499757002 INSTALLER ST1 899864100 REMOVER
ST2 498077400 SYNCHRO CONE REMOV- ST2 899714110 REMOVER
ER
(A)
ST1
(B) ST2
ST1
(A)
(C)
MT-00189
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
ST2
MT-00190
(A) Press
5MT-58
MAIN SHAFT ASSEMBLY (SINGLE-RANGE)
MANUAL TRANSMISSION AND DIFFERENTIAL
D: ASSEMBLY NOTE:
1) Assemble each sleeve and hub assembly. Align the groove in baulk ring with shifting insert.
NOTE: (A) (D) (E)
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