torque SUBARU FORESTER 2004 Service Repair Manual

4AT(H4DOTC)-62
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
M: DTC P0736 REVERSE INCORRECT RATIO
DTC DETECTING CONDITION:
Vehicle speed sensor malfunction and torque converter turbine speed sensor malfunction, etc. or control
valve malfunction.
TROUBLE SYMPTOM:
 Shift point is too high or too low.
 Excessive shift shock.
 Tight corner “braking” phenomenon.
 Gear is not shifted to reverse.
 Gear position is held by fail safe function.
Step Check Yes No
1 PREPARE SUBARU SELECT MONITOR.Do you have a Subaru Select
Monitor?Go to step 2.Go to step 5.
2 CHECK ACCELERATOR PEDAL POSITION
SENSOR.
1) Connect the Subaru Select Monitor to data
link connector.
2) Turn the ignition switch to ON.
3) Read the value of accelerator pedal posi-
tion sensor on Subaru Select Monitor.Does the value of accelerator
pedal position sensor change
from 0% to 100% smoothly
when throttle was operated from
fully closing to fully opening?Go to step 3.Check accelerator
pedal position sen-
sor. 4AT(H4DOTC)-94,
DTC P1708
THROTTLE POSI-
TION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
3 CHECK FRONT VEHICLE SPEED SENSOR.
1) Lift-up the vehicle and place rigid racks.
2) Start the engine.
3) Move the select lever “D” range and slowly
increase vehicle speed.
NOTE:
The speed difference between front and rear
wheels may light ABS warning light, but this indi-
cates no malfunction. When AT control diagnosis
is finished, perform the ABS memory clearance
procedure of on-board diagnostics system.Does the vehicle speed dis-
played by Subaru Select Moni-
tor almost correspond with
vehicle speed indicated by
combination meter?Go to step 4.Check the front
vehicle speed sen-
sor.
4 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
1) Move the select lever to “P” or “N” range.
2) Idle the engine.Does the turbine speed sen-
sor revolution displayed by
Subaru Select Monitor almost
correspond with engine revolu-
tion indicated by tachometer?There are mal-
functions in TCM,
TCM connector
poor contact or
transmission
assembly mechan-
ical malfunction.Check the torque
converter turbine
speed sensor cir-
cuit.
5 CHECK ACCELERATOR PEDAL POSITION
SENSOR.
1) Turn the ignition switch to ON.
2) Fully close the throttle.
3) Measure the voltage between TCM and
chassis ground.
Connector & terminal
(B55) No. 19 (+) — Chassis ground (
−):Is the voltage 0.8 — 1.2 V? Go to step 6.Check the acceler-
ator pedal position
sensor circuit.
4AT(H4DOTC)-94,
DTC P1708
THROTTLE POSI-
TION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>

4AT(H4DOTC)-63
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
6 CHECK ACCELERATOR PEDAL POSITION
SENSOR.
1) Fully close the throttle.
2) Measure the voltage between TCM and
chassis ground.
Connector & terminal
(B55) No. 19 (+) — Chassis ground (
−):Is the voltage 3.3 — 4.6 V? Go to step 7.Check the acceler-
ator pedal position
sensor circuit.
4AT(H4DOTC)-94,
DTC P1708
THROTTLE POSI-
TION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
7 CHECK FRONT VEHICLE SPEED SENSOR.
Check according to DTC P0720 procedure.Is the front vehicle speed sen-
sor circuit normal?Go to step 8.Repair or replace
the front vehicle
speed sensor.
8 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
Check according to DTC P0715 procedure.Is the torque converter turbine
speed sensor circuit normal?There is malfunc-
tion in TCM, TCM
connector poor
contact, or trans-
mission assembly
mechanical mal-
function.Repair or replace
the torque converter
turbine speed sen-
sor circuit. Step Check Yes No

4AT(H4DOTC)-64
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF
DTC DETECTING CONDITION:
 Lock up clutch malfunction
 Locking of valve
TROUBLE SYMPTOM:
Lock up is not operated.
Step Check Yes No
1 CHECK LOCK UP DUTY SOLENOID CIR-
CUIT.
Check according as DTC P0743 procedure.Is there malfunction? Repair or replace
the lock up duty
solenoid circuit.Go to step 2.
2 CHECK INHIBITOR SWITCH CIRCUIT.
Check according as DTC P0705 procedure.Is there malfunction? Repair or replace
the inhibitor switch
circuit.Go to step 3.
3 CHECK STOP LIGHT SWITCH CIRCUIT.
Check according as DTC P0719 and DTC
P0724 procedure.Is there malfunction? Repair or replace
the stop light
switch circuit.Go to step 4.
4 CHECK ATF TEMPERATURE SENSOR CIR-
CUIT.
Check according to DTC P0712 and DTC
P0713 procedure.Is there malfunction? Repair or replace
the ATF tempera-
ture sensor circuit.Go to step 5.
5 PREPARE SUBARU SELECT MONITOR.Do you have a Subaru Select
Monitor?Go to step 6.Go to step 9.
6 CHECK ACCELERATOR PEDAL POSITION
SENSOR.
1) Connect the Subaru Select Monitor to data
link connector.
2) Turn the ignition switch to ON.
3) Read the value of accelerator pedal posi-
tion sensor on Subaru Select Monitor display.Does the value of accelerator
pedal position sensor change
from 0% to 100% smoothly
when throttle was operated from
fully closing to fully opening?Go to step 7.Check the acceler-
ator pedal position
sensor circuit.
7 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
1) Move the select lever to “P” or “N” range.
2) Idle the engine.Does the turbine revolution dis-
played by Subaru Select Moni-
tor almost correspond with
engine revolution indicated by
tachometer?Go to step 8.Check the torque
converter turbine
speed sensor cir-
cuit.
8 CHECK ENGINE SPEED SIGNAL.
Idle the engine.Does the turbine revolution dis-
played by Subaru Select Moni-
tor almost correspond with
engine revolution indicated by
tachometer?There is malfunc-
tion in TCM, TCM
connector poor
contact or trans-
mission assembly
mechanical mal-
fuction.Check the engine
speed signal cir-
cuit.
9 CHECK ACCELERATOR PEDAL POSITION
SENSOR.
Check according to DTC P1708, DTC 1709
and DTC P1714 procedure.Is there a malfunction? Go to step 10.Repair or replace
the accelerator
pedal position sen-
sor circuit.
10 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
Check according to DTC P0715 procedure.Is there a malfunction? Go to step 11.Repair or replace
the torque converter
turbine speed sen-
sor circuit.
11 CHECK ENGINE SPEED SIGNAL.
Check according to DTC P0725 procedure.Is there a malfunction? Repair or replace
the engine speed
signal circuit. There is malfunc-
tion in TCM, TCM
connector poor
contact or trans-
mission assembly
mechanical mal-
function.

4AT(H4DOTC)-65
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL
DTC DETECTING CONDITION:
Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No “lock-up” (after engine warm-up).
WIRING DIAGRAM:
Step Check Yes No
1 CHECK DTC.Are multiple DTCs indicated? Go to another
DTC.Go to step 2.
2 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from TCM and
transmission.
3) Measure the resistance of harness
between TCM and transmission connector.
Connector & terminal
(B56) No. 5 — (B11) No. 12:Is the resistance less than 1
Ω?Go to step 3.Repair the open
circuit in harness
between TCM and
transmission con-
nector.
AT-01117
B11
B56
AT12
1
234
56
78
9
1314
15
20
19 1716 10 1112
18
5
B56
B11
AT12
T4 TCM12 4
12 78 956 34
10 11 12 19 20 21
29 30 31 13 14 15 16 17
27 2818
22 23 24 25 26
13
4562
LOCK-UP
DUTY
SOLENOID
TRANSMISSION

4AT(H4DOTC)-127
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
Excessive time lag occurs when select lever is shifted from “N”
to “R” range. Control valve
 Low & reverse clutch
 Reverse clutch
 Line pressure linear solenoid
 Seal ring
 Front gasket of transmission case
Vehicle does not start in any shift range (engine stalls). Parking brake mechanism
 Planetary gear
Vehicle does not start in any shift range (engine revving up). Strainer
 Line pressure linear solenoid
 Control valve
 Drive pinion
 Hypoid gear
Axle shaft
 Differential gear
 Oil pump
 Input shaft
 Output shaft
 Planetary gear
Drive plate
 ATF level too low
 Front gasket of transmission case
Vehicle does not start in “R” range only (engine revving up). Select cable
 Select lever
 Line pressure linear solenoid
 Control valve
 Low & reverse clutch
 Reverse clutch
Vehicle does not start in “R” range only (engine stalls). Low clutch
2-4 brake
 Planetary gear
 Parking brake mechanism
Vehicle does not start in “D”, “3” range only (engine revving up). Low clutch
 One-way clutch
Vehicle does not start in “D”, “3” or “2” range only (engine rev-
ving up).Low clutch
Vehicle does not start in “D”, “3” or “2” range only (engine
stalls).Reverse clutch
Vehicle starts in “R” range only (engine revving up).  Control valve
Acceleration during standing starts is poor (high stall rpm). Control valve
 Low clutch
 Reverse clutch
 ATF level too low
 ATF deterioration
 Front gasket of transmission case
 Differential gear oil level too high or too low
Acceleration during standing starts is poor (low stall rpm). Oil pump
 Torque converter one-way clutch
 Engine performance
Acceleration is poor when select lever is in “D”, “3” or “2” range
(normal stall rpm).TCM
 Control valve
High clutch
2-4 brake
 Planetary gear
Acceleration is poor when select lever is in “R” (normal stall
rpm). Control valve
High clutch
2-4 brake
 Planetary gear Symptom Problem parts

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)-129
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
Slippage occurs from 1st to 2nd gear.TCM
 Accelerator pedal position sensor
 2-4 brake duty solenoid
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
2-4 brake
Shock occurs from 2nd to 3rd gear.TCM
 Torque converter turbine speed sensor
 Accelerator pedal position sensor
 2-4 brake duty solenoid
 ATF temperature sensor
 Line pressure linear solenoid
 Low & reverse duty solenoid
 Control valve
High clutch
2-4 brake
 ATF deterioration
 Engine performance
 High clutch duty solenoid
Slippage occurs from 2nd to 3rd gear.TCM
 Accelerator pedal position sensor
 2-4 brake duty solenoid
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
High clutch
2-4 brake
 Low & reverse duty solenoid
Shock occurs from 3rd to 4th 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
 Low clutch duty solenoid
2-4 brake
 ATF deterioration
 Engine performance
Slippage occurs from 3rd to 4th gear.TCM
 Accelerator pedal position sensor
 2-4 brake duty solenoid
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
2-4 brake
Shock occurs when select lever is shifted from “3” to “2” range.TCM
 Torque converter turbine speed sensor
 Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Control valve
 2-4 brake duty solenoid
2-4 brake
 ATF deterioration
 High clutch 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-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of main shaft rear plate
Snap ring to counter washer clearance :
0.05 — 0.35 mm (0.0020 — 0.0138 in)
Input shaft holder adjustment
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque :
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6
ft-lb)
5. INPUT SHAFT ASSEMBLY
Snap ring (Outer-28) to ball bearing clear-
ance :
0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Inner-68) to bearing clearance :
0 — 0.12 mm (0 — 0.0047 in)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub
clearance :
0.060 — 0.100 mm (0.0024 — 0.0039 in)
Drive pinion shim
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
32295AA0310.150
(0.0059) 32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069) 32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079) 32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089) 32295AA1010.500
(0.0197)
Main shaft rear plate
Dimension “A” mm (in) Part No. Mark
4.00 — 4.13
(0.1575 — 0.1626) 32294AA041 1
3.87 — 3.99
(0.1524 — 0.1571) 32294AA051 2
Snap ring (Outer-19)
Part No. Thickness mm (in)
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
Dimension “D” mm (in) Number of shim
52.50 — 53.11
(2.0669 — 2.0909)—
52.00 — 52.49
(2.0472 — 2.0665)1
51.26 — 51.99
(2.0181 — 2.0468)2
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
Snap ring (Inner-68)
Part No. Thickness mm (in)
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
Snap ring (Outer-25)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)

5MT-7
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
 Transmission case tightening torque
(1) Transmission case ASSY (Single-
range)(9) Oil seal (16) High-low cable bracket A (Dual-
range)
(10) Clamp
(2) Gasket (11) Pitching stopper bracket (17) High-low cable bracket B (Dual-
range)
(3) Drain plug (12) Clip
(4) Snap ring (Outer) (13) Oil level gauge (Non-turbo model) (18) Oil level gauge (Turbo model)
(5) Speedometer driven gear (14) Oil seal (Dual-range)
(6) Washer (15) Transmission case ASSY (Dual-
range)Tightening torque: N·m (kgf-m, ft-lb)
(7) Speedometer shaftT: 44 (4.5, 32.5) (Aluminum gasket)
(8) Snap ring (Outer)70 (7.1, 51.6) (Copper gasket)
Bolt No. Bolt sizeTightening torque:
N·m (kgf-m, ft-lb)
<5> to <15> 8 mm 25 (2.5, 18.1)
<1> to <4>
<16>, <17> 10 mm 39 (4.0, 28.9)
MT-00003