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)

<< Back | Home

Most service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.




Image preview - the first page of the document
Main Shaft Assembly (Single-Range)


>> Download Main Shaft Assembly (Single-Range) documenatation <<

Text preview - extract from the document
                         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)
Position the open ends of spring 120



◦ Jabse Service Manual Search 2020 ◦ Jabse Pravopis ◦ Other service manual resources online : FixyaeServiceinfo