fuse SUBARU FORESTER 2004 Service Owners Manual

4AT(H4DOTC)-114
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK FWD SWITCH.When the fuse is inserted to
FWD switch, does LED light
up?Go to step CHECK
POWER SWITCH.
4AT(H4DOTC)-
116, CHECK
POWER SWITCH,
Diagnostic Proce-
dure without Diag-
nostic Trouble
Code (DTC).>Go to step 2.
2 CHECK FWD INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.Is the FWD indicator light bulb
OK?Go to step 3.Check the combi-
nation meter.
Combination
Meter Assembly.>
3 CHECK HARNESS CONNECTOR BETWEEN
TCM AND FWD SWITCH.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from TCM and
FWD switch.
3) Measure the resistance of harness
between TCM and FWD switch connector.
Connector & terminal
(B56) No. 17 — (F27) No. 36:Is the resistance less than 1
Ω?Go to step 4.Repair the open
circuit in harness
between TCM and
FWD switch con-
nector.
4 CHECK HARNESS CONNECTOR BETWEEN
TCM AND FWD SWITCH.
Measure the resistance of harness connector
between TCM and body to make sure that cir-
cuit does not short.
Connector & terminal
(B56) No. 17 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 5.Repair the short
circuit in harness
between TCM and
FWD switch con-
nector.
5 CHECK HARNESS CONNECTOR BETWEEN
FWD SWITCH AND CHASSIS GROUND.
Measure the resistance of harness between
FWD switch and chassis ground.
Connector & terminal
(F27) No. 35 — Chassis ground:Is the resistance less than 1
Ω?Go to step 6.Repair the open
circuit in harness
between FWD
switch connector
and chassis
ground.
6 CHECK INPUT SIGNAL FOR TCM.
1) Turn the ignition switch to OFF.
2) Connect the connector to FWD switch and
TCM.
3) Turn the ignition switch to ON.
4) Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
Connector & terminal
(B56) No. 17 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 7.Go to step 11.
7 CHECK INPUT SIGNAL FOR TCM.
Measure the signal voltage for TCM while
removing the fuse from FWD switch connector.
Connector & terminal
(B56) No. 17 (+) — Chassis ground (
−):Is the voltage more than 10.5
V?Go to step 8.Replace the TCM.
Transmission Con-
trol Module
(TCM).>
8 CHECK HARNESS CONNECTOR BETWEEN
TCM AND COMBINATION METER.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from TCM and
combination meter.
3) Measure the resistance of harness between
TCM and combination meter connector.
Connector & terminal
(B56) No. 14 — (i10) No. 22:Is the resistance less than 1
Ω?Go to step 9.Repair the open
circuit in harness
between TCM and
combination meter
and poor contact
in coupling con-
nector.

4AT(H4DOTC)-115
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
9 CHECK HARNESS CONNECTOR BETWEEN
TCM AND COMBINATION METER.
Measure the resistance of harness connector
between TCM and chassis ground to make
sure that circuit does not short.
Connector & terminal
(B56) No. 14 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 10.Repair the short
circuit in harness
between TCM and
combination meter
connector.
10 CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
1) Turn the ignition switch to OFF.
2) Connect the connector to TCM and combi-
nation meter.
3) Turn the ignition switch to ON.
4) Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
Connector & terminal
(B56) No. 14 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 11.Go to step 12.
11 CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
Measure the signal voltage for TCM while
removing the fuse from FWD switch connector.
Connector & terminal
(B56) No. 14 (+) — Chassis ground (
−):Is the voltage more than 10.5
V?Go to step 12.Replace the TCM.
Transmission Con-
trol Module
(TCM).>
12 CHECK POOR CONTACT.Is there poor contact in FWD
switch circuit?Repair the poor
contact.Replace the TCM.
Transmission Con-
trol Module
(TCM).> Step Check Yes No

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-64
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Case
11) Remove the main shaft assembly and input
shaft assembly.
NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.
12) 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.
B: INSTALLATION
1. SINGLE-RANGE
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the needle bearing knock pin hole into trans-
mission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
THREE BOND 1215 (Part No. : 004403007) or
equivalent6) Tighten the seven teen bolts with bracket, clip,
etc. as shown in the figure.
NOTE:
 Insert the bolts from bottom and tighten the nuts
at top.
 Put the cases together so that drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
 Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm (0.39 in) bolt
39 N·m (4.0 kgf-m, 28.9 ft-lb)
7) Tighten the bearing attachment bolts.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
(A) Main shaft ASSY
(B) Input shaft ASSY
MT-00170
(A)
(B)
MT-00162
(9)(7)
(5)
(1)
(2)(16)
(17)
(11)
(3)
(4)
(12)
(8) (6) (10) (14) (15)(13)
MT-00172
MT-00158

5MT-96
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
21.Front Differential Assembly
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. 62, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
Single-range model
For Single-Range.>
Dual-range model
For Dual-Range.>
6) 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.
7) Remove the differential side retainers using ST.
ST 499787000 WRENCH ASSY
8) Remove the bearing outer race from transmis-
sion case.
ST 398527700 PULLER ASSY
B: INSTALLATION
1) Insert the bearing outer race to transmission
case.
NOTE:
Apply the transmission gear oil to outer surface of
bearing outer race.
2) Install the differential side retainers using ST.
ST 499787000 WRENCH ASSY
3) Install the differential assembly.
NOTE:
 Be careful not to fold the sealing lip of oil seal.
 Wrap the right and left spline sections of axle
shaft with vinyl tape to prevent scratches.
4) Install the main shaft assembly. 69, INSTALLATION, Main Shaft Assembly For Sin-
gle-Range.>
5) Install the drive pinion assembly. 69, INSTALLATION, Main Shaft Assembly For Sin-
gle-Range.>
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.>
MT-00162
MT-00176
ST
MT-00162

5MT-112
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
2. DIFFERENTIAL
Symptom Possible cause Remedy
1. Broken differential (case, gear, bear-
ing, etc.)
N
OTE:
Noise will develop and finally it will be-
come impossible to continue to run due to
broken pieces obstructing the gear revo-
lution. (a) Insufficient or improper oil Disassemble the differential and replace
broken components and at the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutch Readjust the bearing preload and back-
lash and face contact of gears.
(c) Improper adjustment of taper roller
bearingAdjust.
(d) Improper adjustment of drive pinion
and hypoid driven gear Adjust.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions. Add recommended oil to specified level.
Do not use the vehicle under severe oper-
ating conditions.
(f) Loose hypoid driven gear clamping
boltsTighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas, bear-
ing, body, etc. are easily mistaken for the
differential noise. Pay special attention to
the hypoid gear noise because it is easily
confused with other gear noises. There
are the following four kinds of noises.
 Gear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
 Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
 Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
 Noise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc. (a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinionReplace as a set.
Readjust the bearing preload.
(d) Loose roller bearing Readjust the hypoid driven gear to drive
pinion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential caseReplace.
(f) Worn washer and differential pinion
shaftReplace.