SUBARU FORESTER 2004 Service Repair Manual

CS-6
CONTROL SYSTEM
General Description
3. DRIVE SELECT LEVER
(1) Knob (6) SpringTightening torque: N·m (kgf-m, ft-lb)
(2) Cushion (7) Lever ASSYT1: 1.6 (0.16, 1.2)
(3) Plate ASSY (8) ClipT2: 18 (1.8, 13.0)
(4) Bushing (9) Clevis pin
(5) Cable (10) Snap pin
CS-00004
(4)
(3)
(2) (1)
(7)
(9)(10)
(6)
(5)
(8)
T2
T1T2

CS-7
CONTROL SYSTEM
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 Use SUBARU genuine fluid, grease etc. or the
equivalent. Do not mix grease etc. with that of an-
other grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply grease onto sliding or revolution surfaces
before installation.
 Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or cloth between the part and vise.
 Before disconnecting electrical connectors, be
sure to disconnect the ground cable from battery.

CS-8
CONTROL SYSTEM
Select Lever
2. Select Lever
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Shift the select lever to “N” range.
4) Lift-up the vehicle.
5) Remove the rear exhaust pipe and muffler.
 Non-turbo model
Pipe.> fler.>
 Turbo model
haust Pipe.> AL, Muffler.>
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever, and then
remove the cable bracket.
8) Lower the vehicle.
9) Remove the console box. MOVAL, Console Box.>
10) Disconnect the connectors, then remove the
four bolts to take out the select lever assembly from
body.
B: INSTALLATION
1) Mount the select lever onto vehicle body.
2) Tighten the four bolts to install the select lever to
vehicle body, then connect the connector.
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
3) Install the console box. LATION, Console Box.>
4) Shift the select lever to “N” range.
5) Lift-up the vehicle.
6) Shift the range select lever to “N” range.
7) Insert the thread portion of inner cable into con-
nector hole of the select lever, and fix the outer ca-
ble end to bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
8) Adjust the select cable position. ADJUSTMENT, Select Cable.>
9) After completion of fitting, make sure the select
lever operates smoothly all across the operating
range.
10) Install the heat shield cover. (If equipped)
11) Install the rear exhaust pipe and muffler.
 Non-turbo model
haust Pipe.> TION, Muffler.>
 Turbo model
Exhaust Pipe.> STALLATION, Muffler.>
12) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
and inhibitor switch. MENT, Select Cable.> MENT, Inhibitor Switch.>
(1) The engine starts operating when select le-
ver is in “P” range, but not in other ranges.
(2) The back-up light is lit when the select lever
is in “R” range, but not in other ranges.
(3) Select lever and indicator ranges are matched.
(A) Adjusting nut
(B) Cable bracket
CS-00017(B)(A)
CS-00018
CS-00168

CS-9
CONTROL SYSTEM
Select Lever
C: DISASSEMBLY
1. NON-TURBO MODEL
1) Remove the grip.
2) Remove the indicator light, and then remove the
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.
3) Remove the blind.
4) Remove the clips, and then remove the guide
plate.5) Remove the grommet, and then extract the
spring pin.
6) Remove the arm assembly, and then take away
the select lever assembly from base plate.
(A) Grip
(B) Indicator cover
(C) Indicator light
(A) Clip
(B) Guide plate
CS-00020
( A )
( B )
( C )
CS-00021
(A)(A) (B)
(A) Spring pin
(B) Arm ASSY
(A) Arm ASSY
(B) Select lever ASSY
(C) Base plate
(A)
(B)
CS-00027
CS-00109
(A) (B)
(C)

CS-10
CONTROL SYSTEM
Select Lever
2. TURBO MODEL
1) Remove the packing.
2) Remove the grip.
3) Remove the indicator light, and then remove the
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.
4) Remove the blind.
5) Remove the cover.
6) Remove the clips, and then remove the guide
plate.7) Remove the clamp, and then remove the N−R
lock solenoid.
8) Remove the lock plate B mounting bolt.
9) Remove the lock plate A, B, C and bushing.
(A) Grip
(B) Indicator cover
(C) Indicator light
(A) Clip
(B) Cover
(A) Clip
(B) Guide plate
CS-00020
( A )
( B )
( C )
CS-00105
(A)
(B)
CS-00021
(A)(A) (B)
(A) Clamp
(B) N−R lock solenoid
(A) Lock plate A
(B) Lock plate B
(C) Bushing
(D) Lock plate C
CS-00352
(B)
(A)
CS-00353
CS-00368
(A)(C)
(D)(C)
(B)
(C)

CS-11
CONTROL SYSTEM
Select Lever
10) Remove the cushion plate.
11) Remove the grommet, and then extract spring
pin.
12) Remove the arm assembly, and then take
away the select lever assembly from base plate.13) Remove the detent spring, and then remove
the detent arm.
(A) Spring pin
(B) Arm ASSY
(A) Arm ASSY
(B) Select lever ASSY
(C) Base plate
CS-00093
(A)
(B)
CS-00027
CS-00109
(A) (B)
(C)
(A) Detent arm
(B) Detent spring
CS-00110
(A)
(B)

CS-12
CONTROL SYSTEM
Select Lever
D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to each part. CS-3, AT SELECT LEVER, COMPONENT, Gener-
al Description.>
CAUTION:
Apply grease [SUNCALL] around the axle of lock
plate (Turbo model). Apply grease to only indi-
cated portion.
3) Assemble is in the reverse order of disassembly.
NOTE:
 Refer to “COMPOTNENT” for tightening torque.
tion.>
 Tighten the lock plate bolt uniformly. After installa-
tion, put the base plate upside down, and then push
the lock plate up. Make sure the lock plate falls by its
weight when releasing it. If not, retighten the bolt.
4) After completion of fitting, transfer the select le-
ver to range “P” — “1”, then check the indicator and
select lever are matched, the pointer and position
mark are matched and the operating force.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Cor-
rect or replace if defective.
2) Confirm the following parts for operating condi-
tion before assembly. Moving condition of the se-
lect lever assembly, it should move smoothly.
CS-00355
CS-00356

CS-13
CONTROL SYSTEM
Select Cable
3. Select Cable
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Prior to removal, shift the select lever to “N”
range.
4) Lift-up the vehicle.
5) Remove the front and center exhaust pipe.
 Non-turbo model
Pipe.>
 Turbo model
haust Pipe.>
6) Remove the heat shield cover. (If equipped)
7) Remove the snap pin from range select lever.
8) Remove the plate assembly from transmission
case.9) Disconnect the select cable from range select le-
ver, and then remove the cable bracket.
10) Remove the select cable from plate assembly.
B: INSTALLATION
1) Install the select cable to plate assembly.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Install the select cable to range select lever.
3) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
(A) Select cable
(B) Plate ASSY
(C) Clamp
CS-00036
(C)(B) (A)
(E) (D)
CS-00037
(A)
(C)
(B)
(A) Adjusting nut
(B) Cable bracket
(A) Select cable
(B) Plate ASSY
CS-00017(B)(A)
CS-00039
(A)
(B)
T

CS-14
CONTROL SYSTEM
Select Cable
4) Install the snap pin to range select lever.
5) Shift the select lever to “N” range, then adjust the
select cable position. MENT, Select Cable.>
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe.
 Non-turbo model
haust Pipe.>
 Turbo model
Exhaust Pipe.>
C: INSPECTION
Check the removed cable and replace if damaged,
rusty, or defective.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deterio-
ration.
5) Shift the select lever from “P” range to “1” range.
You should be able to feel the detentes in each
range. If the detentes cannot be felt or the range
pointer is improperly aligned, adjust the cable.
D: ADJUSTMENT
1) Set the vehicle on a lift.
2) Shift the select lever to “N” range.
3) Lift-up the vehicle.
4) Remove the rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped)6) Loosen the adjusting nuts on each side.
7) Turn the adjusting nut B until it lightly touches
the bushing assembly.
8) While preventing the adjusting nut B from mov-
ing with a wrench, tighten the adjusting nut A.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
CS-00036
(C)(B) (A)
(E) (D)
(A) Adjusting nut A
(B) Adjusting nut B
(A) Front side
(B) Select lever
(C) Bushing ASSY
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
(A) Adjusting nut A
(B) Adjusting nut B
CS-00040
(A) (B)
CS-00041
(A)(B)
(C)
(D)
(E)(F)
CS-00042
(A)
(B)

CS-15
CONTROL SYSTEM
Select Cable
9) After completion of fitting, make sure that the se-
lect lever operates smoothly all across the operat-
ing range.
10) Install in the reverse order of removal.