ECU SUBARU FORESTER 2004 Service Repair Manual

4AT(H4DOTC)-96
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
 RHD model
Step Check Yes No
1 CHECK ENGINE GROUND TERMINALS.Have engine ground terminals
been tightened securely?Go to step 2.Tighten the engine
ground terminals.
AT-01852
B55
12 7
8956 34
10 11 12
19 20 2113 14 15 16
17 18 22 23 24
E13
B122
B21
B134B55 TCM
A:B135 B:B137 D: ECMB136 C:
E2B22
E3
B21
13 1415
16
12 34
56 78
9
10
11
12
13161415
3
1
3
210
19
C18
C16
C35D2D1D7
B12B4C19A6 A7B1
EE
1225
1320
20
19
18
B22
1
234
56
78
9
1314
15
20
19 1716 10 111218
JOINT CONNECTOR
THROTTLE
POSITION
SENSOR
B3151
2
6
ACCELERATOR
PEDAL POSITION
SENSOR
123
E13
20
20
20
25
25
25
B315
1
23456
B136
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
C:
B137
567
82 1
94 310
22 23 11 12 13 14 15
24 25
2616 17
18 19 20 21
27 28 29 30 31
D:
B122
12345678
B135 B:
567
82 1
94 310
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 35
B134 A:
56 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31

4AT(H4DOTC)-102
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
 RHD model
Step Check Yes No
1 CHECK ENGINE GROUND TERMINALS.Have the engine ground termi-
nals been tightened securely?Go to step 2.Tighten the engine
ground terminals.
AT-01852
B55
12 7
8956 34
10 11 12
19 20 2113 14 15 16
17 18 22 23 24
E13
B122
B21
B134B55 TCM
A:B135 B:B137 D: ECMB136 C:
E2B22
E3
B21
13 1415
16
12 34
56 78
9
10
11
12
13161415
3
1
3
210
19
C18
C16
C35D2D1D7
B12B4C19A6 A7B1
EE
1225
1320
20
19
18
B22
1
234
56
78
9
1314
15
20
19 1716 10 111218
JOINT CONNECTOR
THROTTLE
POSITION
SENSOR
B3151
2
6
ACCELERATOR
PEDAL POSITION
SENSOR
123
E13
20
20
20
25
25
25
B315
1
23456
B136
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
C:
B137
567
82 1
94 310
22 23 11 12 13 14 15
24 25
2616 17
18 19 20 21
27 28 29 30 31
D:
B122
12345678
B135 B:
567
82 1
94 310
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 35
B134 A:
56 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31

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

5MT-19
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498247001 MAGNET BASE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with DIAL GAUGE (498247100).
498247100 DIAL GAUGE  Used for measuring backlash between side
gear and pinion, and hypoid gear.
 Used with MAGNET BASE (498247001).
498427400 STOPPER Used for securing the drive pinion shaft assem-
bly and driven gear assembly when removing the
drive pinion shaft assembly lock nut.
498787100 MAIN SHAFT
STOPPERUsed for removing and installing transmission
main shaft lock nut. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498247001
ST-498247100
ST-498247400
ST-498787100

5MT-34
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
16) Remove the bolts which holds right upper side
of transmission to engine.
17) Remove the front and center exhaust pipes.
(Non-turbo model) AL, Front Exhaust Pipe.>
18) Remove the center exhaust pipe. (Turbo mod-
el). Exhaust Pipe.>
19) Remove the rear exhaust pipe and muffler.
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
20) Remove the heat shield cover. (Non-turbo
model)
21) Remove the hanger bracket from right side of
transmission.
22) Remove the propeller shaft. REMOVAL, Propeller Shaft.>23) Remove the gear shift rod and stay from trans-
mission.
(1) Disconnect the stay from transmission.
(2) Disconnect the gear shift rod from transmis-
sion.
24) Disconnect the ATF cooler hose from transmis-
sion side oil cooler pipe. (Model with oil pump)
25) Disconnect the stabilizer link from transverse
link.
26) Remove the bolts securing ball joint of trans-
verse link to housing, and then separate the trans-
verse link and housing.
MT-00073
MT-00074
(A) Stay
(B) Gear shift rod
MT-00075
(A)
(B)
(B)
FS-00026

5MT-73
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb) 2. TURBO MODEL
1) Assemble each sleeve and hub assembly.
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on transmission main
shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
(A) 5th needle bearing
(B) 5th drive gear
(C) 5th baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th-Rev hub ASSY
(D) 5th gear side
(A) 3rd needle bearing
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
MT-00191 (D) (C)(B) (A)
MT-00200
(A)
(B)
(C) (D)(E)
(F)

5MT-75
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Single-Range
9) Make sure the synchro cone rotates smoothly af-
ter press-fitting.
ST 499757002 INSTALLER
10) Install the synchro cone stopper and snap ring
to 5th-Rev sleeve and hub assembly.11) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
13) Secure the lock nuts in two places after tighten-
ing.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
(B) (A)
(C)
ST
MT-00188
(A) (B)
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)

5MT-81
MANUAL TRANSMISSION AND DIFFERENTIAL
Main Shaft Assembly For Dual-Range
11) Install rest of the parts to the rear section of
transmission main shaft.
NOTE:
Align the convex part in baulk ring with shifting in-
sert.
12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
13) Install the needle bearing on main shaft.14) Install the rest of parts to the front section of
transmission main shaft.
NOTE:
 Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
 Face the grooved side toward input gear.
 Align the high-low baulk ring’s groove with shift-
ing insert.
15) Install a new snap ring to the rod section of
transmission main shaft using ST1 and ST2.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1 499757002 INSTALLER
ST2 499757001 SNAP RING GUIDE
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
(A) (B) (C) (D)
(E)
(F)
(A) Ball
(B) Input low gear spacer
(C) Needle bearing
(D) Low input gear
(E) Friction damper
(F) High-low baulk ring
(G) Sleeve and hub ASSY
Snap ring
Part No. Thickness mm (in)
805025058 2.37 (0.0933)
805025051 2.42 (0.0953)
805025052 2.47 (0.0972)
805025053 2.52 (0.0992)
805025054 2.57 (0.1012)
805025055 2.62 (0.1031)
805025056 2.67 (0.1051)
805025057 2.72 (0.1071)
MT-00225
(F)
(G)(C)(B)(A)
(D)
(E)
(F)

5MT-92
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
11) Install the washer using ST1, ST2 and press.
NOTE:
 Discard the old lock nuts, replace with new ones.
 Secure the lock nut in four places.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
12) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.13) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because the spacer must be installed in
proper direction.
(A) Washer
MT-00261
(A)
ST1
ST2
MT-00262
(A) Driven shaft
(B) Drive pinion shaft
(C) Drive pinion collar
(D) Needle bearing (25×30×20)
(E) Adjusting washer No. 2 (25×36×4)
(F) Thrust bearing (25×37.5×3)
(G) Adjusting washer No. 1 (25×36×t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)

5MT-104
MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse Idler Gear
23.Reverse Idler Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. es and Harness.>
3) Remove the transfer case with extension case
assembly. Case and Extension Case Assembly.>
4) Remove the transmission case. 62, REMOVAL, Transmission Case.>
5) Remove the drive pinion shaft assembly. to 5MT-87, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) Remove the main shaft assembly.
Single-Range model
For Single-Range.>
Dual-Range model
For Dual-Range.>
7) Remove the differential assembly. 96, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. 106, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the Rev
idler gear shaft, reverse idler gear and washer.
10) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse shifter lever, reverse idler
gear and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall. to 5MT-104, INSTALLATION, Reverse Idler Gear.>
and Idler Gear.>
3) Install the shifter forks and rods. 106, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. 96, INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
Single-Range model
sembly For Single-Range.>
Dual-Range model
sembly For Dual-Range.>
6) Install the drive pinion shaft assembly. 5MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
7) Install the transmission case. INSTALLATION, Transmission Case.>
8) Install the transfer case with extension case as-
sembly. fer Case and Extension Case Assembly.>
9) Install the back-up light switch and neutral posi-
tion switch. Switches and Harness.>
10) Install the manual transmission assembly to ve-
hicle. Transmission Assembly.>
(A) Straight pin
(B) Rev idler gear shaft
(C) Rev idler gear
(D) Washer
MT-00303
(A)(B)
(C)
(D)
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
MT-00304
(A)
(B)
(D)
(C)