2004 SUBARU FORESTER meter

4AT(H4DOTC)-118
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
2 CHECK POWER SWITCH OPERATION.When the POWER switch is
turned to ON, does LED light
up?Go to step CHECK
HOLD SWITCH.
4AT(H4DOTC)-
120, CHECK
HOLD SWITCH,
Diagnostic Proce-
dure without Diag-
nostic Trouble
Code (DTC).>Go to step 3.
3 CHECK POWER INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.
3) Remove the POWER indicator light bulb
from combination meter.Is the POWER indicator light
bulb OK?Go to step 4.Replace the
POWER indicator
light bulb. IDI-10, Combina-
tion Meter Assem-
bly.>
4 CHECK POWER SWITCH GROUND CIR-
CUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from POWER
switch.
3) Measure the resistance of harness connector
between POWER switch and chassis ground.
Connector & terminal
LHD model
(R92) No. 4 — Chassis ground:
RHD model
(B133) No. 4 — Chassis ground:Is the resistance less than 1
Ω?Go to step 5.Repair the open
circuit in harness
between POWER
switch and chas-
sis ground.
5 CHECK POWER SWITCH.
1) Turn the POWER switch to ON.
2) Measure the resistance between terminals
of POWER switch.
Te r m i n a l s
No. 5 — No. 4:Is the resistance less than 1
Ω?Go to step 6.Replace the
POWER switch.
6 CHECK POWER SWITCH.
1) Turn the POWER switch to OFF.
2) Measure the resistance between terminals
of POWER switch.
Te r m i n a l s
No. 5 — No. 4:Is the resistance more than1
MΩ?Go to step 7.Replace the
POWER switch.
7 CHECK HARNESS CONNECTOR BETWEEN
TCM AND POWER SWITCH.
Measure the resistance of harness connector
between TCM and POWER switch.
Connector & terminal
(B54) No. 8 — (B133) No. 5:Is the resistance less than 1
Ω?Go to step 8.Repair the open
circuit in harness
between TCM and
POWER switch
connector.
8 CHECK HARNESS CONNECTOR BETWEEN
TCM AND POWER SWITCH.
Measure the resistance of harness connector
between TCM connector and chassis ground.
Connector & terminal
(B54) No. 8 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 9.Repair the short
circuit in harness
between TCM and
POWER switch
connector.
9 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connectors to TCM and
POWER switch.
2) Turn the ignition switch to ON (engine OFF).
3) Measure the signal voltage for TCM while
turning POWER switch to OFF.
Connector & terminal
(B54) No. 8 (+) — Chassis ground (–):Is the voltage more than 10 V? Go to step 10.Replace the TCM.
Transmission Con-
trol Module
(TCM).> Step Check Yes No

4AT(H4DOTC)-120
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
C: CHECK HOLD SWITCH
DIAGNOSIS:
 The LED does not come on when HOLD switch is ON.
 The HOLD switch circuit is open or shorted.
TROUBLE SYMPTOM:
 The 2nd gear is not held.
 Failure of vehicle to start in 2nd gear except 1st range.
WIRING DIAGRAM:
 LHD model
AT-01858
SBF-4 SBF-1
No.14
i10
i2
B37
B54
R92
B14
9
5
E
B54
123456
78 9 10 1112
13
14
15 16 17
1819
2021
2223
24
2526
2728
2930
i10
POWEROFF HOLD
3
4
E
HOLD
R92
12
34
56219
32
B38
1234
56
10 11 12 13 14 157
16
23 3019 20
22 26 27 28 298
17
24 3118
25
12i3
B38
20B98
R2
26
POWER AND HOLD
SWITCH IGNITION
SWITCHBATTERY
COMBINATION
METER
TCM
123
8910411 12
13 14 15 1656
7
17
B98
B37
1234
5678
910
11
121314
1516 17 1819
20 2122

4AT(H4DOTC)-121
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
 RHD model
Step Check Yes No
1 CHECK HOLD SWITCH OPERATION.When the HOLD switch is
turned to OFF, does LED light
up?Go to step 5.Go to step 2.
AT-01859
SBF-4 SBF-1
No.14
i10
i3
B38
B54
B133
B15
C7
16
E
B54
123456
78 9 10 1112
13
14
15 16 17
1819
2021
2223
24
2526
2728
2930
i10
POWEROFF HOLD
3
4
E
HOLD
i2
B133
12
34
56219
32
i3
1234
56
10 11 12 13 14 157
16
23 3019 20
22 26 27 28 298
17
24 3118
25
6i2
B37
26
POWER AND HOLD
SWITCH IGNITION
SWITCHBATTERY
COMBINATION
METER
TCM
123
8910411 12
13 14 15 1656
7
17
123 8
910411 12 13 14 15 165671718

4AT(H4DOTC)-122
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
2 CHECK HOLD SWITCH OPERATION.When the HOLD switch is
turned to ON, does LED light
up?Go to step Check
Kick-Down Switch.
4AT(H4DOTC)-
124, CHECK
KICK–DOWN
SWITCH, Diagnos-
tic Procedure with-
out Diagnostic
Trouble Code
(DTC).>Go to step 3.
3 CHECK HOLD INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.
3) Remove the HOLD indicator light bulb from
combination meter.Is the HOLD indicator light bulb
OK?Go to step 4.Replace the HOLD
indicator light bulb.
Combination
Meter Assembly.>
4 CHECK HOLD SWITCH GROUND LINE.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from HOLD switch.
3) Measure the resistance of harness connec-
tor between HOLD switch and chassis ground.
Connector & terminal
LHD model
(R92) No. 4 — Chassis ground:
RHD model
(B133) No. 4 — Chassis ground:Is the resistance less than 1
Ω?Go to step 5.Repair the open
circuit in harness
between HOLD
switch and chas-
sis ground.
5 CHECK HOLD SWITCH.
1) Turn the HOLD switch to ON.
2) Measure the resistance between terminals
of HOLD switch.
Te r m i n a l s
No. 4 — No. 3:Is the resistance less than 1
Ω?Go to step 6.Replace the HOLD
switch.
6 CHECK HOLD SWITCH.
1) Turn the HOLD switch to OFF.
2) Measure the resistance between terminals
of HOLD switch.
Te r m i n a l s
No. 4 — No. 3:Is the resistance more than 1
MΩ?Go to step 7.Replace the HOLD
switch.
7 CHECK HARNESS CONNECTOR BETWEEN
TCM AND HOLD SWITCH.
1) Disconnect the connector TCM and combi-
nation meter.
2) Measure the resistance of harness connec-
tor between TCM and HOLD switch.
Connector & terminal
LHD model
(B54) No. 2 — (R92) No. 3:
RHD model
(B54) No. 2 — (B133) No. 3:Is the resistance less than 1
Ω?Go to step 8.Repair the open
circuit in harness
between TCM and
HOLD switch con-
nector and poor
contact in cou-
pling connector.
8 CHECK HARNESS CONNECTOR BETWEEN
TCM AND COMBINATION METER.
Measure the resistance of harness connector
between TCM and combination meter.
Connector & terminal
(B54) No. 6 — (i10) No. 14:Is the resistance less than 1
Ω?Go to step 9.Repair the open
circuit in harness
between TCM and
combination
meter, and poor
contact in cou-
pling connector. Step Check Yes No

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

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

5MT-21
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
499827000 PRESS Used for installing speedometer oil seal when
installing speedometer cable to transmission.
499857000 5TH DRIVEN GEAR
REMOVERUsed for removing 5th driven gear.
499877000 RACE 4-5
INSTALLER Used for installing 4th needle bearing race and
ball bearing onto transmission main shaft.
 Used with REMOVER (899714110). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499787000
ST-499827000
ST-499857000
ST-499877000

5MT-25
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899824100 PRESS Used for installing speedometer shaft oil seal.
499987100 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
899984103 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
498057300 INSTALLER Used for installing extension oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899824100
ST-499987100
ST-899984103
ST-498057300