Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 2004 3 - Transmission Manual and Differential Reverse Idler Gear

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Reverse Idler Gear


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                                            REVERSE IDLER GEAR
                                                                MANUAL TRANSMISSION AND DIFFERENTIAL

20.Reverse Idler Gear                                      B: INSTALLATION
                                                           1) Install the reverse shifter lever, reverse idler
A: REMOVAL                                                 gear and reverse idler gear shaft, and secure with
1) Remove the manual transmission assembly                 straight pin.
from vehicle.                                     NOTE:
2) Remove the back-up light switch and neutral po-         Be sure to install the reverse idler shaft from rear
sition switch. 
3) Remove the transfer case with extension case
assembly.                                                     (A)
4) Remove the transmission case. 
5) Remove the drive pinion shaft assembly.                                                                          (C)
6) Remove the main shaft assembly.
                                                                                                    MT-00304
                                                  (A)    Reverse shifter lever
7) Remove the differential assembly. 
                                                                  (C)    Reverse idler gear shaft
8) Remove the shifter forks and rods. 
9) Pull out the straight pin, and remove the Rev           2) Inspect and adjust the clearance between re-
idler gear shaft, reverse idler gear and washer.           verse idler gear and transmission case wall. 
                                                           and 
                                                           3) Install the shifter forks and rods. 
                                                           4) Install the differential assembly. 
                                      (D)                  5) Install the main shaft assembly.
                                                           
                                            MT-00303
                                                           6) Install the drive pinion shaft assembly. 
      (B)     Rev idler gear shaft
                                                           7) Install the transmission case. 
      (D)     Washer
                                                           8) Install the transfer case with extension case as-
10) Remove the reverse shifter lever.                      sembly. 
                                                           9) Install the back-up light switch and neutral posi-
                                                           tion switch. 
                                                           10) Install the manual transmission assembly to ve-
                                                           hicle. 




                                                       5MT-79
                                        REVERSE IDLER GEAR
MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION                                            D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse       1) Select the appropriate reverse shifter lever from
side. Inspect the clearance between reverse idler        the table below, and adjust until the gap between
gear and transmission case wall.                         the reverse idler gear and transmission case wall is
If out of specification, select the appropriate re-      within specification.
verse shifter lever and adjust.
                                                         Clearance A:
Clearance A:                                               6.0 -- 7.5 mm (0.236 -- 0.295 in)
  6.0 -- 7.5 mm (0.236 -- 0.295 in)




                                                                              A
                    A


                                                                                                    MT-00305
                                         MT-00305
                                                                          Reverse shifter lever
2) After installing a suitable reverse shifter lever,
                                                               Part No.       Mark                Remarks
shift into neutral. Inspect the clearance between re-
verse idler gear and transmission case wall.                 32820AA070         7           Further from case wall
If out of specification, select the appropriate washer       32820AA080         8           Standard
and adjust.                                                  32820AA090         9           Closer to case wall

Clearance:                                               2) Select the appropriate washer from the table be-
  0 -- 0.5 mm (0 -- 0.020 in)                            low, and adjust until the gap between the reverse
                                                         idler gear and transmission case wall is within
                                                         specification.
                                                         Clearance:
                                                           0 -- 0.5 mm (0 -- 0.020 in)




                                         MT-00306

3) Check the reverse idler gear and shaft for dam-
age. Replace if damaged.

                                                                                                    MT-00306

                                                                                  Washer
                                                                   Part No.                Thickness mm (in)
                                                                  803020151                    0.4 (0.016)
                                                                  803020152                    1.1 (0.043)
                                                                  803020153                    1.5 (0.059)
                                                                  803020154                    1.9 (0.075)
                                                                  803020155                    2.3 (0.091)




                                                    5MT-80



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