Page 2305 of 2870
CS-20
CONTROL SYSTEM
MT Gear Shift Lever
3) Remove the snap ring from bushing B, and then
disconnect the stay.
4) Remove the boot from gear shift lever.
5) Remove the bushing and cushion rubber from
stay.
6) Remove the O-ring, and then remove the bush-
ing B.7) Draw out the spring pin, and then remove the
bushing A from gear shift lever.
D: ASSEMBLY
1) Clean all parts before assembly.
2) Mount the bushing and cushion rubber on the
stay.
(A) Snap ring
(B) Bushing B
(C) Stay
(A) Bushing
(B) Stay
(C) Cushion rubber
(A) O-ring
(B) O-ring
(C) Bushing B
CS-00057
(A)(B)
(C)
CS-00058
(A)
(B)
(C)
CS-00059
(C)
(B)
(A)
(A) Spring pin
(B) Bushing A
(A) Bushing
(B) Cushion rubber
CS-00060
(B)
(A)
CS-00061
(A)
(B)
Page 2306 of 2870
CS-21
CONTROL SYSTEM
MT Gear Shift Lever
3) Mount each part; boot, O-ring, bushing A, spac-
er, bushing B, bushing and spring pin on the gear
shift lever.
NOTE:
Always use new O-rings.
Apply grease [SUNLIGHT 2 (Part No. 003602010)
or equivalent] to the inner and side surfaces of the
bush when installing the spacer.
4) Insert the gear shift lever into boot hole.
5) Install the snap ring and stay to bushing B.6) Tighten with a lock wire to the extent that the
boot will not come off.
NOTE:
Always use new lock wire.
7) Insert the rod into boot hole.
8) Connect the rod to gear shift lever.
Tightening torque:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
(A) Boot
(B) O-ring
(C) Bushing
(D) Spacer
(E) Bushing A
(F) Bushing B
(G) Spring pin
(H) O-ring
(A) Snap ring
(B) Bushing B
CS-00062
(F)(D)(C)
(E)
(G)
(H)
(B)
(A)
CS-00165
(A)(B)
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)
Page 2307 of 2870
CS-22
CONTROL SYSTEM
MT Gear Shift Lever
E: INSPECTION
1) Check each part (bushing, cushion rubber, spacer,
boot, stay, rod, etc.) for deformation, damage and
wear. Repair or replace any defective part. Determine
defective parts by comparing with new parts.
2) Check the swing torque of the rod connected to
gear shift lever.
If the torque exceeds specification, replace the
bushing or retighten nuts.
Swing torque:
3.7 N (0.38 kgf, 0.83 lb) or less3) Check that there is no excessive play and that
parts move smoothly.
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
(A) Center of rotation
(B) Swing torque
(C)
(D)(A) (F) (A)
CS-00064
(E)(B)
CS-00065
(A)
(B)
Page 2308 of 2870

CS-23
CONTROL SYSTEM
MT Drive Select Lever
6. MT Drive Select Lever
A: REMOVAL
1) Apply parking brake and place chocks to hold
wheels.
2) Disconnect the ground cable from battery.
3) Shift the drive select lever to HI position.
4) Remove the knob.
5) Remove the console box.
MOVAL, Console Box.>
6) Remove the bolt installing drive select lever as-
sembly on body.
7) Remove the flange nut and clip, and then dis-
connect the cable from lever assembly.
B: INSTALLATION
1) Install the drive select cable to lever assembly,
and then fasten it with a clip.
2) Install the drive select lever.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
3) Shift the drive select lever to HI position.
4) Insert the cable eye end bolt into lever arm slit.
5) Tighten the nut where cable eye end bolt comes
to a stop.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) Flange nut
(B) Lever ASSY
(C) Clip
CS-00102
CS-00067
(C)(A)(B)
(A) Flange nut
(B) Lever ASSY
(C) Clip
(A) HI position
(A) Cable eye end bolt
(B) Lever arm
CS-00067
(C)(A)(B)
CS-00068
(A)
CS-00069
(A) (B)
Page 2309 of 2870
CS-24
CONTROL SYSTEM
MT Drive Select Lever
6) Install in the reverse order of removal.
C: DISASSEMBLY
1) Remove the spring.
2) Remove the lever, cushion and bushing.
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Make sure the select lever moves smoothly.
E: INSPECTION
1) Make sure the select lever moves smoothly. If it
does not move smoothly, repair or replace it.
2) Make sure the drive select lever is not damaged.
If it is damaged, repair or replace it.
(A) Spring
(A) Washer
(B) Bushing
(C) Plate ASSY
(D) Cushion
(E) Lever ASSY
CS-00070
(A)
CS-00071
(E)(C)
(D)(B)(A)
Page 2310 of 2870

CS-25
CONTROL SYSTEM
Drive Select Cable
7. Drive Select Cable
A: REMOVAL
1) Remove the drive select lever.
REMOVAL, MT Drive Select Lever.>
2) Remove the intake duct.
REMOVAL, Air Intake Duct.>
3) Remove the air cleaner case.
6, REMOVAL, Air Cleaner Case.>
4) Remove the snap pin and clevis pin.
5) Loosen the nut and disconnect the cable from
cable bracket.
6) Disconnect the cable from transmission clamp.
7) Remove the cable from the under side of vehi-
cle.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Make sure the drive select lever operates prop-
erly.
C: INSPECTION
1) Shift the transmission to HI or LO position by
moving the drive select lever. If it does not move,
adjust the cable.
Drive Select Cable.>
2) Make sure the cable moves smoothly. If it catch-
es or fails to work properly, repair or replace it.
3) Check the cable for damage.
D: ADJUSTMENT
1) Shift the drive select lever to HI position.
2) Remove the drive select lever knob.
3) Remove the console box.
MOVAL, Console Box.>
4) Remove the nut.
5) Make sure the transmission is in HI position. If it is
not, pull the cable to put transmission in HI position.
6) Tighten the nut in the location where cable end
bolt stops naturally.
Tightening torque:
18 N·m (1. 8 kgf-m, 13.0 ft-lb)
7) Shift the transmission to HI or LO position by
moving the drive select lever. If it does not move,
readjust the cable.
(A) Snap pin
(B) Clevis pin
(C) Nut
CS-00103(A) (B) (C)
CS-00073
CS-00104
CS-00104
Page 2311 of 2870
CS-26
CONTROL SYSTEM
General Diagnostic Table
8. General Diagnostic Table
A: INSPECTION
Symptom Possible cause Remedy
Select lever Starter does not run. Adjust the select cable and inhibitor switch, or
inspect the circuit.
Back-up light does not light up. Adjust the select cable and inhibitor switch, or
inspect the circuit.
Page 2312 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