replace brake SUBARU FORESTER 2004 Service Owner's Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1305 of 2870
EN(H4SO)-207
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK OPERATION OF BRAKE LIGHT.Does the brake light come on
when depressing the brake
pedal?Go to step 2.Repair or replace
the brake light cir-
cuit.
2 CHECK HARNESS BETWEEN TCM AND
BRAKE LIGHT SWITCH CONNECTOR.
1) Disconnect the connectors from TCM and
brake light switch.
2) Measure the resistance of harness
between TCM and brake light switch connec-
tor.
Connector & terminal
WITHOUT CRUISE CONTROL
(B55) No. 12 — (B64) No. 2:
WITH CRUISE CONTROL
(B55) No. 12 — (B65) No. 3:Is the resistance less than 1
Ω?Go to step 3.Repair or replace
the harness and
connector.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
TCM and brake
light switch con-
nector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND
BRAKE LIGHT SWITCH CONNECTOR.
Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
(B55) No. 12 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 4.Repair ground
short circuit in har-
ness between
TCM and brake
light switch con-
nector.
4 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connectors to TCM and brake
light switch.
2) Measure the voltage between TCM and
chassis ground.
Connector & terminal
(B55) No. 12 (+) — Chassis ground (
−):Is the voltage less than 1 V
when releasing the brake
pedal?Go to step 5.Adjust or replace
the brake light
switch.
SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM.
Measure the voltage between TCM and chas-
sis ground.
Connector & terminal
(B55) No. 12 (+) — Chassis ground (
−):Is the voltage more than 10 V
when depressing the brake
pedal?Go to step 6.Adjust or replace
the brake light
switch.
SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
6 CHECK POOR CONTACT.
Check poor contact in TCM connector.Is there poor contact in TCM
connector?Repair poor con-
tact in TCM con-
nector.Replace the TCM.
trol Module
(TCM).>
Page 1307 of 2870
EN(H4SO)-209
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BJ:DTC P0734 GEAR 4 INCORRECT RATIO
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Shift point too high or too low.
Engine brake not effected in 3rd range.
Excessive shift shock.
Excessive tight corner braking.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
Step Check Yes No
1 CHECK ANY OTHER DTC ON DISPLAY.Is any other DTC displayed? Inspect the rele-
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”.
of Diagnostic Trou-
ble Code (DTC).>Go to step 2.
2 CHECK THROTTLE POSITION SENSOR
CIRCUIT.
Check the throttle position sensor circuit.
TION SENSOR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>Is there any trouble in throttle
position sensor circuit?Repair or replace
the throttle posi-
tion sensor circuit.Go to step 3.
3 CHECK FRONT VEHICLE SPEED SENSOR
CIRCUIT.
Check front vehicle speed sensor circuit.
SPEED SENSOR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>Is there any trouble in front
vehicle speed sensor circuit?Repair or replace
the front vehicle
speed sensor cir-
cuit.Go to step 4.
4 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR CIRCUIT.
Check torque converter turbine speed sensor
circuit.
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>Is there any trouble in torque
converter turbine speed sensor
circuit?Repair or replace
the torque con-
ver ter turbine
speed sensor cir-
cuit.Go to step 5.
5 CHECK POOR CONTACT.
Check poor contact in TCM connector.Is there poor contact in TCM
connector?Repair poor con-
tact in TCM con-
nector.Go to step 6.
6 CHECK MECHANICAL TROUBLE.
Check mechanical trouble in automatic trans-
mission.Is there any mechanical trou-
ble in automatic transmission?Repair or replace
the automatic
transmission.
Road Test.>Replace the TCM.
trol Module
(TCM).>
Page 1308 of 2870
EN(H4SO)-210
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BK:DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
Step Check Yes No
1 CHECK ANY OTHER DTC ON DISPLAY.Is any other DTC displayed? Inspect the rele-
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”.
of Diagnostic Trou-
ble Code (DTC).>Go to step 2.
2 CHECK LOCK-UP DUTY SOLENOID CIR-
CUIT.
Check lock-up duty solenoid circuit.
SOLENOID, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>Is there any trouble in lock-up
duty solenoid circuit?Repair or replace
the lock-up duty
solenoid circuit.Go to step 3.
3 CHECK THROTTLE POSITION SENSOR
CIRCUIT.
Check the throttle position sensor circuit.
TION SENSOR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>Is there any trouble in throttle
position sensor circuit?Repair or replace
the throttle posi-
tion sensor circuit.Go to step 4.
4 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR CIRCUIT.
Check torque converter turbine speed sensor
circuit.
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>Is there any trouble in torque
converter turbine speed sensor
circuit?Repair or replace
the torque con-
ver ter turbine
speed sensor cir-
cuit.Go to step 5.
5 CHECK ENGINE SPEED INPUT CIRCUIT.
Check engine speed input circuit.
NAL, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>Is there any trouble in engine
speed input circuit?Repair or replace
the engine speed
input circuit.Go to step 6.
6 CHECK INHIBITOR SWITCH CIRCUIT.
Check inhibitor switch circuit.
Diagnostic Procedure without Diagnostic Trou-
ble Code (DTC).>Is there any trouble in inhibitor
switch circuit?Repair or replace
the inhibitor switch
circuit.Go to step 7.
7 CHECK BRAKE LIGHT SWITCH CIRCUIT.
Check brake light switch circuit.
Diagnostic Procedure without Diagnostic Trou-
ble Code (DTC).>Is there any trouble in brake
light switch circuit?Repair or replace
the brake light
switch circuit.Go to step 8.
Page 2384 of 2870
4AT-71
AUTOMATIC TRANSMISSION
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
19.Shift Solenoids, Duty Sole-
noids and ATF Temperature
Sensor
A: REMOVAL
1. SHIFT SOLENOID AND DUTY SOLE-
NOID
1) Lift-up the vehicle.
2) Clean the transmission exterior.
3) Drain the ATF completely.
4) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
5) Remove the oil pan.
6) Disconnect the solenoid and duty solenoid con-
nectors.7) Remove the solenoid and duty solenoid.
2. ATF TEMPERATURE SENSOR
For removal procedure of the ATF temperature
sensor, refer to “Front Vehicle Speed Sensor”.
B: INSTALLATION
1. SHIFT SOLENOID AND DUTY SOLE-
NOID
1) Insert the solenoid and duty solenoid into the
specified position.
(A) Oil pan
(B) Drain plug (ATF)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-00080
(A)(B)
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)
Page 2526 of 2870
4AT(H4SO)-67
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
6 CHECK POOR CONTACT.Is there poor contact in 2-4
brake timing solenoid circuit?Repair the poor
contact.Replace the TCM.
trol Module
(TCM).>
7 CHECK 2-4 BRAKE TIMING SOLENOID (IN
TRANSMISSION).
1) Remove the transmission connector from
bracket.
2) Lift-up or raise the vehicle and support with
rigid rack.
N
OTE:
Raise all wheels off ground.
3) Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
4) Remove the oil pan, and disconnect con-
nector from 2-4 brake timing solenoid.
5) Measure the resistance between 2-4 brake
timing solenoid connector and transmission
ground.
Te r m i n a l s
No. 1 — Transmission ground:Is the resistance 10 — 16 Ω? Go to step 8.Replace the 2-4
brake timing sole-
noid.
noids, Duty Sole-
noids and ATF
Temperature Sen-
sor.>
8 CHECK HARNESS CONNECTOR BETWEEN
2-4 BRAKE TIMING SOLENOID AND
TRANSMISSION.
Measure the resistance of harness between 2-
4 brake timing solenoid and transmission con-
nector.
Connector & terminal
(AT8) No. 1 — (T4) No. 4:Is the resistance less than 1
Ω?Go to step 9.Repair the open
circuit in harness
between 2-4 brake
timing solenoid
and transmission
connector.
9 CHECK HARNESS CONNECTOR BETWEEN
2-4 BRAKE TIMING SOLENOID AND
TRANSMISSION.
Measure the resistance of harness between 2-
4 brake timing solenoid connector and trans-
mission ground.
Connector & terminal
(T4) No. 4 — Transmission ground:Is the resistance more than 1
MΩ?Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in 2-4
brake timing sole-
noid and transmis-
sion.Repair the short
circuit harness
between 2-4 brake
timing solenoid
and transmission
connector. Step Check Yes No
Page 2532 of 2870
4AT(H4SO)-73
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
8 CHECK OUTPUT SIGNAL EMITTED FROM
TCM USING SUBARU SELECT MONITOR.
1) Turn the ignition switch to ON (engine
OFF).
2) Throttle is fully open.
3) Read the data of 2-4 brake duty solenoid
using Subaru Select Monitor.Is the value less than 25%? Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 9.
9 CHECK POOR CONTACT.Is there poor contact in 2-4
brake duty solenoid circuit?Repair the poor
contact.Replace the TCM.
trol Module
(TCM).>
10 CHECK 2-4 BRAKE DUTY SOLENOID (IN
TRANSMISSION).
1) Remove the transmission connector from
bracket.
2) Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
3) Remove the oil pan, and disconnect con-
nector from 2-4 brake duty solenoid.
4) Measure the resistance between 2-4 brake
duty solenoid connector and transmission
ground.
Te r m i n a l s
No. 1 — Transmission ground:Is the resistance 2.0 — 4.5 Ω? Go to step 11.Replace the 2-4
brake duty sole-
noid.
noids, Duty Sole-
noids and ATF
Temperature Sen-
sor.>
11 CHECK HARNESS CONNECTOR BETWEEN
TRANSMISSION AND 2-4 BRAKE DUTY SO-
LENOID.
Measure the resistance of harness between 2-
4 brake duty solenoid and transmission con-
nector.
Connector & terminal
(T4) No. 9 — (AT7) No. 1:Is the resistance less than 1
Ω?Go to step 12.Repair the open
circuit in harness
between 2-4 brake
duty solenoid and
transmission con-
nector.
12 CHECK HARNESS CONNECTOR BETWEEN
TRANSMISSION AND 2-4 BRAKE DUTY SO-
LENOID.
Measure the resistance of harness between
transmission connector and transmission
ground.
Connector & terminal
(T4) No. 9 — Transmission ground:Is the resistance more than 1
MΩ?Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in line
pressure duty
solenoid and
transmission.Repair the short
circuit in harness
between 2-4 brake
duty solenoid and
transmission con-
nector. Step Check Yes No
Page 2545 of 2870
4AT(H4SO)-86
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK FWD SWITCH.
Connect the Subaru Select Monitor to data link
connector, and then change to LED display
screen.When the fuse is inserted to
FWD switch, does LED light
up?Go to step CHECK
BRAKE SWITCH.
CHECK BRAKE
SWITCH, Diag-
nostic Procedure
without Diagnostic
Trouble Code
(DTC).>Go to step 2.
2 CHECK FWD INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Disconnect the TCM connector.
3) Turn the ignition switch to ON.
4) Short the combination meter connector to
chassis ground.
CAUTION:
Be sure to short through fuse.
Connector & terminal
(i10) No. 22 — Chassis ground:Does the FWD indicator light
illuminate?Go to step 3.Inspect the combi-
nation meter.
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
(B55) No. 20 — (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
(B55) No. 20 — 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 TCM and FWD
switch.
3) Turn the ignition switch to ON.
4) Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
Connector & terminal
(B55) No. 20 (+) — 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
(B55) No. 20 (+) — Chassis ground (
−):Is the voltage 6 — 9.1 V? Go to step 8.Replace the TCM.
trol Module
(TCM).>
Page 2654 of 2870
4AT(H4DOTC)-78
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
9 CHECK POOR CONTACT.Is there poor contact in 2-4
brake duty solenoid circuit?Repair the poor
contact.Replace the TCM.
trol Module
(TCM).>
10 CHECK 2-4 BRAKE DUTY SOLENOID (IN
TRANSMISSION).
1) Remove the transmission connector from
bracket.
2) Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
3) Remove the oil pan, and disconnect con-
nector from 2-4 brake duty solenoid.
4) Measure the resistance of harness
between 2-4 brake duty solenoid connector
and transmission ground.
Connector & terminal
(AT12) No. 6 — Transmission ground:Is the resistance 2.0 — 4.5 Ω? Go to step 11.Replace the control
valve body.
Valve Body.>
11 CHECK HARNESS CONNECTOR BETWEEN
2-4 BRAKE DUTY SOLENOID AND TRANS-
MISSION.
Measure the resistance of harness between 2-
4 brake duty solenoid and transmission con-
nector.
Connector & terminal
(T4) No. 3 — (AT12) No. 6:Is the resistance less than 1
Ω?Go to step 12.Repair the open
circuit in harness
between 2-4 brake
clutch duty sole-
noid and transmis-
sion connector.
12 CHECK HARNESS CONNECTOR BETWEEN
2-4 BRAKE DUTY SOLENOID AND TRANS-
MISSION.
Measure the resistance of harness between
transmission connector and transmission
ground.
Connector & terminal
(T4) No. 3 — Transmission ground:Is the resistance more than 1
MΩ?Even if the POWER
indicator light was
blinking, the circuit
has returned to a
normal condition at
this time. A tempo-
rary poor contact of
the connector or
harness may be the
cause. Repair the
harness or connec-
tor in 2-4 brake duty
solenoid and trans-
mission.Repair the short
circuit harness
between 2-4 brake
duty solenoid and
transmission con-
nector. Step Check Yes No
Page 2661 of 2870
4AT(H4DOTC)-85
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
8 CHECK OUTPUT SIGNAL FROM TCM US-
ING SUBARU SELECT MONITOR.
1) Shift the select lever to “1” range.
2) Read the data of low & reverse duty sole-
noid.Is the value 61.5%? Even if the POWER
indicator light was
blinking, the circuit
has returned to a
normal condition at
this time. A tempo-
rary poor contact of
the connector or
harness may be the
cause. Repair the
harness or connec-
tor in TCM and
transmission.Go to step 9.
9 CHECK POOR CONTACT.Is there poor contact in low &
reverse duty solenoid circuit?Repair the poor
contact.Replace the TCM.
trol Module
(TCM).>
10 CHECK LOW & REVERSE BRAKE DUTY
SOLENOID (IN TRANSMISSION).
1) Remove the transmission connector from
bracket.
2) Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
3) Remove the oil pan, and disconnect con-
nector from low & reverse brake duty solenoid.
4) Measure the resistance between low &
reverse brake duty solenoid connector and
transmission ground.
Connector & terminal
(AT12) No. 1 — Transmission ground:Is the resistance 2.0 — 4.5 Ω? Go to step 11.Replace the control
valve body.
Valve Body.>
11 CHECK HARNESS CONNECTOR BETWEEN
TRANSMISSION AND LOW & REVERSE
BRAKE DUTY SOLENOID.
Measure the resistance of harness between
low & reverse brake duty solenoid and trans-
mission connector.
Connector & terminal
(T4) No. 6 — (AT12) No. 1:Is the resistance less than 1
Ω?Go to step 12.Repair the open
circuit in harness
between low &
reverse brake duty
solenoid and
transmission con-
nector.
12 CHECK HARNESS CONNECTOR BETWEEN
TRANSMISSION AND LOW & REVERSE
BRAKE DUTY SOLENOID.
Measure the resistance of harness between
transmission connector and transmission
ground.
Connector & terminal
(T4) No. 6 — Transmission ground:Is the resistance more than 1
MΩ?Even if the POWER
indicator light was
blinking, the circuit
has returned to a
normal condition at
this time. A tempo-
rary poor contact of
the connector or
harness may be the
cause. Repair the
harness or connec-
tor in low & reverse
brake duty solenoid
and transmission.Repair the short
circuit in harness
between low &
reverse brake duty
solenoid and
transmission con-
nector. Step Check Yes No
Page 2857 of 2870
CL-31
CLUTCH SYSTEM
Clutch Fluid
8. Clutch Fluid
A: INSPECTION
1) Park the vehicle on a level surface.
2) Inspect the fluid level using scale on the outside
of the reservoir tank. If the level is below “MIN”, add
fluid to bring it up to “MAX”, and also inspect for
leakage.
B: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or DOT4
brake fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
For convenience and safety, it is advisable to
have two men working.
1) Remove the air cleaner case and air chamber.
2) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
4) Refill the reservoir tank with new recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
5) Drain fluid in the same method as air bleeding.
6) Refill the brake fluid before reservoir tank be-
comes empty, and drain contaminated fluid again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00076
(A)
(B) (C)