differential SUBARU FORESTER 2004 Service Manual PDF
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2702 of 2870
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
Page 2703 of 2870
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
Page 2704 of 2870
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
Page 2709 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL
Page 2712 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL
Page 2713 of 2870
MANUAL TRANSMISSION AND
DIFFERENTIAL
5MT
Page
1. General Description ....................................................................................2
2. Transmission Gear Oil ..............................................................................31
3. Manual Transmission Assembly ...............................................................32
4. Transmission Mounting System ................................................................39
5. Oil Seal......................................................................................................41
6. Differential Side Retainer Oil Seal.............................................................42
7. Switches and Harness ..............................................................................43
8. Vehicle Speed Sensor...............................................................................46
9. Preparation for Overhaul ...........................................................................47
10. Oil Pump ...................................................................................................48
11. Transfer Case and Extension Case Assembly..........................................50
12. Transfer Drive Gear ..................................................................................54
13. Transfer Driven Gear ................................................................................56
14. Center Differential .....................................................................................58
15. Reverse Check Sleeve..............................................................................59
16. Transmission Case ...................................................................................62
17. Main Shaft Assembly For Single-Range ...................................................69
18. Main Shaft Assembly For Dual-Range ......................................................77
19. Input Shaft Assembly ................................................................................83
20. Drive Pinion Shaft Assembly .....................................................................87
21. Front Differential Assembly .......................................................................96
22. Speedometer Gear..................................................................................103
23. Reverse Idler Gear ..................................................................................104
24. Shifter Fork and Rod ...............................................................................106
25. Counter Gear ..........................................................................................109
26. General Diagnostic..................................................................................111
Page 2714 of 2870
5MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil
Model2.0 L Non-
turbo2.5 L Non-
turbo2.0 L Turbo
2.5 L Turbo
Except
EuropeEurope
Ty p e5×2-forward speeds with syn-
chromesh and 2-reverse5-forward speeds with synchromesh and 1-
reverse
Transmission gear ratio1st 3.454
2nd 2.062 1.947
3rd 1.448 1.366
4th 1.088 0.972
5th 0.825 0.780 0.738
Reverse 3.333
Auxiliary transmission gear ratioHigh 1.000 —
Low 1.447 1.196 —
Front reduction gear FinalType of gear Hypoid
Gear ratio 4.111 4.444
Rear reduction gearTransferType of gear Helical
Gear ratio 1.000 1.000 1.081 1.000
FinalType of gear Hypoid
Gear ratio 4.111 4.444 4.111 4.444
Front differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 4.02 (4.2 US qt, 3.5 Imp qt)3.52 (3.7 US
qt, 3.1 Imp
qt)3.92 (4.1 US
qt, 3.4 Imp
qt)3.52 (3.7 US
qt, 3.1 Imp
qt)
(1) Item
(2) Transmission gear oil
(3) API classification
(4) SAE viscosity No. and applicable temperature
MT-00001
(1)
(4) GL-5(3) (2)
( C)( F)-30 -26 -15 15
90
85W
80W
75W -9025 30 -5 0-22-1523328659775
Page 2715 of 2870
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)
Page 2716 of 2870
5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
7. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH)
wall clearance :
6.0 — 7.5 mm (0.236 — 0.295 in)
After installing a suitable reverse shifter lever, ad-
just the clearance using washers.
Reverse idler gear to transmission case wall
clearance:
0 — 0.5 mm (0 — 0.020 in)
8. SHIFTER FORK AND ROD
Select the suitable shifter forks so that both cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance :
A: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
B: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
9. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Reverse check plate adjustment
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall
Washer (20.5×26×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059) — —
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear
by 0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3 Approach to 2nd gear
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3 Approach to 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)
Part No. Mark Remarks
32812AA201 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA211 No mark Standard
32812AA221 9Become distant from
5th gear by 0.2 mm
(0.008 in)
5th shifter fork (Turbo)
Part No. Mark Remarks
32812AA231 7Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
32812AA251 9Become distant from
5th gear by 0.2 mm
(0.008 in)
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA130 SNeutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 UNeutral position is
closer to reverse gear.
Reverse check plate
Par t No. Mar kAngle
θRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the cen-
ter.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
Page 2717 of 2870
5MT-5
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
10.EXTENSION ASSEMBLY
Thrust washer (50×61×t) to taper roller bearing
table outer race side clearance :
0.2 — 0.3 mm (0.0008 — 0.012 in)
NOTE:
Be sure to set within the standard clearance.
Thrust washer to center differential side
clearance :
0.15 — 0.35 mm (0.0059 — 0.0138 in)
11.FRONT DIFFERENTIAL
Bevel gear to pinion backlash :
0.13 — 0.18 mm (0.0051 — 0.0071 in)
12.TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clear-
ance :
0.01 — 0.15 mm (0.0004 — 0.0059 in)
Thrust washer (50×61×t)
Part No. Thickness mm (in)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
Washer (38.1×50×t)
Par t No.Thickness
mm (in)Par t No.Thickness
mm (in)
8030380210.925 —
0.950
(0.0364 —
0.0374)8030380231.025 —
1.050
(0.0404 —
0.0413)
8030380220.975 —
1.000
(0.0384 —
0.0394)——
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)