lock SUBARU FORESTER 2004 Service Repair Manual

4AT(H4DOTC)-88
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR
WHEEL)
DTC DETECTING CONDITION:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
No lock-up or tight corner “braking” phenomenon.
WIRING DIAGRAM:
AT-01850
2324
B11
AT10
T491713
312
B55 TCM BATTERY
IGNITION
SWITCH
REAR VEHICLE
SPEED SENSOR
ESBF-1
SBF-4 NO.11
123
AT10B11
12 34
5678
9
13 14 15
20 19 1716 10 11 1218
B55
12 7
8956 34
10 11 12
19 20 2113 14 15 16
17 18 22 23 24

4AT(H4DOTC)-126
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
15.Symptom Related Diagnostic
A: INSPECTION
Symptom Problem parts
Starter does not rotate when select lever is in “P” or “N” range,
starter rotates when select lever is in “R”, “D”, “3” or “2” range. Inhibitor switch
 Select cable
 Select lever
 Starter motor and harness
Abnormal noise when select lever is in “P” or “N” range. Strainer
 Transfer duty solenoid
 Oil pump
Drive plate
 ATF level too high or too low
Hissing noise occurs during standing start. Strainer
 ATF level too high or too low
Noise occurs while driving in “D1”.  Final gear
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low Noise occurs while driving in “D2”.
Noise occurs while driving in “D3”. Final gear
 Low & reverse brake
 Reduction gear
 Differential gear oil level too high or too low
Noise occurs while driving in “D4”. Final gear
 Low & reverse brake
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low
Engine stalls while shifting from “1” range to another. Control valve
 Lock-up damper
 Engine performance
 Input shaft
Vehicle moves when select lever is in “N” range. Select cable
 Inhibitor switch
TCM
 Low clutch
Shock occurs when select lever is shifted from “N” to “D” range. Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Low clutch duty solenoid
 Low clutch
TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is shifted from “N”
to “D” range. Control valve
 Low clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket of transmission case
Shock occurs when select lever is shifted from “N” to “R” range. Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
TCM
Harness
 Control valve
 ATF deterioration

4AT(H4DOTC)-128
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
No shift occurs from 1st to 2nd gear.TCM
 Rear vehicle speed sensor
 Front vehicle speed sensor
 Throttle position sensor
 Control valve
2-4 brake
No shift occurs from 2nd to 3rd gear.TCM
 Control valve
High clutch
No shift occurs from 3rd to 4th gear.TCM
 ATF temperature sensor
 Control valve
2-4 brake
Engine brake is not effected when select lever is in “3” range. Inhibitor switch
TCM
 Throttle position sensor
 Control valve
Engine brake is not effected when select lever is in “3” or “2”
range.Control valve
Engine brake is not effected when select lever is in “1” range. Control valve
 Low & reverse brake
Shift characteristics are erroneous. Inhibitor switch
TCM
 Front vehicle speed sensor
 Rear vehicle speed sensor
 Throttle position sensor
 Control valve
 Ground earth
No lock-up occurs.TCM
 Torque converter turbine speed sensor
 Throttle position sensor
 ATF temperature sensor
 Control valve
 Lock-up facing
 Engine speed signal
Parking brake is not effected.  Select cable
 Select lever
 Parking mechanism Shift lever cannot be moved or is hard to move from “P” range.
ATF spurts out. ATF level too high
Differential oil spurts out. Differential gear oil too high
Differential oil level changes excessively. Seal pipe
 Double oil seal
Odor is produced from ATF supply pipe.High clutch
2-4 brake
 Low & reverse clutch
 Reverse clutch
 Lock-up facing
 ATF deterioration
Shock occurs from 1st to 2nd gear.TCM
 Torque converter turbine speed sensor
 Accelerator pedal position sensor
 2-4 brake duty solenoid
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
2-4 brake
 ATF deterioration
 Engine performance
 Low & reverse duty solenoid Symptom Problem parts

4AT(H4DOTC)-130
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
Shock occurs when select lever is shifted from “D” to “1” range.TCM
 Torque converter turbine speed sensor
 Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
 ATF deterioration
 Low & reverse brake duty solenoid
 Low & reverse clutch solenoid
Shock occurs when select lever is shifted from “2” to “1” range.TCM
 Torque converter turbine speed sensor
 Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
 Low & reverse clutch
 ATF deterioration
 2-4 brake duty solenoid
 Low & reverse brake duty solenoid
Shock occurs when accelerator pedal is released at medium
speeds.TCM
 Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
 Lock-up damper
 Engine performance
Vibration occurs during straight-forward operation.TCM
 Lock-up duty solenoid
 Lock-up facing
 Lock-up damper
HOLD switch
Vibration occurs during turns (tight corner “braking” phenome-
non).TCM
 Front vehicle speed sensor
 Rear vehicle speed sensor
 Accelerator pedal position sensor
 ATF temperature sensor
 Transfer clutch
Transfer valve
 Transfer duty solenoid
 ATF deterioration
Harness
HOLD switch
Front wheel slippage occurs during standing starts.TCM
 Front vehicle speed sensor
 Accelerator pedal position sensor
 ATF temperature sensor
 Control valve
 Transfer clutch
Transfer valve
 Transfer pipe
 Transfer duty solenoid
Vehicle is not set in FWD mode.TCM
 Transfer clutch
Transfer valve
 Transfer duty solenoid
Select lever is hard to move. Select cable
 Select lever
 Detente spring
 Manual plate Symptom Problem parts

5MT-8
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. DRIVE PINION ASSEMBLY
(1) Drive pinion shaft (14) 1st driven gear (28) Lock washer
(2) Roller bearing (15) Baulk ring (29) Lock nut
(3) Washer (16) 1st-2nd synchronizer hub (30) Washer
(4) Thrust bearing (17) Insert key (31) Thrust bearing
(5) Needle bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(6) Driven shaft (19) Outer baulk ring (33) Washer
(7) Key (20) Synchro cone (34) Lock washer
(8) Woodruff key (21) Inner baulk ring (35) Lock nut
(9) Drive pinion collar (22) 2nd driven gear
(10) Needle bearing (23) 2nd driven gear bushTightening torque: N·m (kgf-m, ft-lb)
(11) Snap ring (Outer) (Non-turbo
model)(24) 3rd-4th driven gearT1: 30 (3.1, 22.1)
(25) Driven pinion shimT2: 120 (12.2, 88.5)
(12) Washer (Non-turbo model) (26) Roller bearingT3: 260 (26.5, 192)
(13) Sub gear (Non-turbo model) (27) 5th driven gear
MT-00004
(5)
(4)
(1)
(25)(26)(27) (28)(29)
(21)(22)(23)
(31)(30)(32)(33)(34) (24)
(20)(18)
(19)(6)(3)
(2)
(12) (11)
(10)
(9) (8)
(7)
(13)(16)(17)
(14)(15)
T1
T3
(35)T2
(30)

5MT-9
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. MAIN SHAFT ASSEMBLY (SINGLE RANGE)
(1) Oil seal (15) Needle bearing (28) Rev synchro cone
(2) Needle bearing (16) 4th gear thrust washer (29) Ball bearing
(3) Transmission main shaft (17) Double taper roller bearing (30) Synchro cone stopper
(4) Needle bearing (18) 5th gear thrust washer (Non-turbo
model)(31) Snap ring
(5) 3rd drive gear (32) Lock washer
(6) Inner baulk ring (19) 5th needle bearing race (33) Lock nut
(7) 3rd synchro cone (20) Needle bearing (34) Reverse idler gear shaft
(8) Outer baulk ring (21) Main shaft rear plate (35) Straight pin
(9) 3rd-4th coupling sleeve (22) 5th drive gear (36) Reverse idler gear
(10) 3rd-4th synchronizer hub (23) 5th baulk ring (37) Washer
(11) 3rd-4th shifting insert key (24) 5th-Rev shifting insert key
(12) 4th baulk ring (25) 5th-Rev synchronizer hubTightening torque: N·m (kgf-m, ft-lb)
(13) 4th drive gear (26) 5th-Rev coupling sleeveT: 120 (12.2, 88.5)
(14) 4th needle bearing race (27) Rev baulk ring
T
(18)
(19)(20)(21)(22)(23) (24)
(25)(26)(27)(28)(29)(30)(31)(32)(33)
(35)(34)(36)
(37)
(3)
(9)(10)
(4)(5) (2)
(1)
(6)(7)(8)(11)(17)
(12)(13)(14)(15)(16)
MT-00005

5MT-11
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
(1) O-ring (30) Needle bearing (59) Rev synchro cone
(2) High-low counter shaft (31) Input low gear spacer (60) Ball bearing
(3) Knock pin (32) Ball (61) Synchro cone stopper
(4) High-low counter washer (33) Main shaft (62) Snap ring
(5) Counter gear (34) Needle bearing (63) Lock washer
(6) Needle bearing (35) 3rd drive gear (64) Lock nut
(7) Counter gear collar (36) 3rd baulk ring (2.0L model) (65) Reverse idler gear shaft
(8) Snap ring (Outer-19) (37) Inner baulk ring (2.5L model) (66) Straight pin
(9) Input shaft holder (38) 3rd synchro cone (2.5L model) (67) Reverse idler gear
(10) Input shaft shim (39) Outer baulk ring (2.5L model) (68) Washer
(11) Oil seal (40) 3rd-4th coupling sleeve (69) Straight pin
(12) O-ring (41) 3rd-4th synchronizer hub (70) High-low shifter lever
(13) Snap ring (Outer-28) (42) 3rd-4th shifting insert key (71) High-low shifter shaft
(14) Oil squeeze (43) 4th baulk ring (72) Low switch
(15) Straight pin (44) 4th drive gear (73) Gasket
(16) Snap ring (Outer-28) (45) 4th needle bearing race (74) Straight pin
(17) Ball bearing (46) Needle bearing (75) High-low shifter fork
(18) Snap ring (Inner-68) (47) 4th gear thrust washer (76) High-low shifter piece
(19) Input shaft (48) Ball bearing (77) Ball
(20) Needle bearing (49) 5th gear thrust washer (78) Spring
(21) Snap ring (Outer-25) (50) 5th needle bearing race (79) Gasket
(22) High-low baulk ring (51) Needle bearing (80) Plug
(23) High-low coupling sleeve (52) Main shaft rear plate
(24) High-low synchronizer spring (53) 5th drive gearTightening torque: N·m (kgf-m, ft-lb)
(25) High-low synchronizer hub (54) 5th baulk ringT1: 9.75 (0.99, 7.2)
(26) Shifting insert key (55) 5th-Rev shifting insert keyT2: 20 (2.0, 14.5)
(27) High-low baulk ring (56) 5th-Rev synchronizer hubT3: 25 (2.5, 18.1)
(28) Friction damper (57) 5th-Rev coupling sleeveT4: 120 (12.2, 88.5)
(29) Input low gear (58) Rev baulk ring

5MT-12
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
5. SHIFTER FORK AND SHIFTER ROD
(1) Shifter arm (8) Ball (15) Spring
(2) 5th shifter fork (9) 3rd-4th fork rod (16) Snap ring (Outer)
(3) Straight pin (10) Interlock plunger (17) Reverse fork rod arm
(4) Reverse fork rod (11) 1st-2nd fork rod (18) Reverse shifter lever
(5) Checking ball plug (12) 3rd-4th shifter fork
(6) Gasket (13) 1st-2nd shifter forkTightening torque: N·m (kgf-m, ft-lb)
(7) Checking ball spring (14) BallT: 20 (2.0, 14.5)
MT-00007
T
T
T (1)
(2)
(3)
(3)(3) (4)
(5)
(5)
(5) (6)
(6) (6) (7)
(7)
(7) (8)
(8)(8)(9)
(10)(10)
(10)
(11) (12)
(13) (14) (15) (16)(17)(18)

5MT-15
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
8. FRONT DIFFERENTIAL
(1) Drive pinion shaft (7) Differential bevel pinion (13) Retainer lock plate
(2) Hypoid driven gear (8) Roller bearing
(3) Pinion shaft (9) Differential caseTightening torque: N·m (kgf-m, ft-lb)
(4) Straight pin (10) Oil sealT1: 25 (2.5, 18.1)
(5) Washer (11) Differential side retainerT2: 62 (6.3, 45.6)
(6) Differential bevel gear (12) O-ring
MT-00009
(12)(10)
(1)
(2)
T1
T2
(5)
(5)
(6)
(9)
(7)
(7)
(12) (8)
(8)
(13)
(13)(11)
(11) (10)
T1
(4)(3)

5MT-17
MANUAL TRANSMISSION AND DIFFERENTIAL
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, and disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
 Be careful not to burn your hands, because each
part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another 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 gear oil onto sliding or revolution surfaces
before installation.
 Replace deformed or otherwise damaged snap
rings with new ones.
 Before installing O-rings or oil seals, apply suffi-
cient amount of gear oil to avoid damage and defor-
mation.
 Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vis e.
 Avoid damaging the mating surface of the case.
 Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
399411700 ACCENT BALL
INSTALLERUsed for installing reverse shifter rail arm.
899524100 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) PULLER
(2) CAP
ST-399411700
ST-899524100