2004 SUBARU FORESTER light

CS-10
CONTROL SYSTEM
Select Lever
2. TURBO MODEL
1) Remove the packing.
2) Remove the grip.
3) Remove the indicator light, and then remove the
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.
4) Remove the blind.
5) Remove the cover.
6) Remove the clips, and then remove the guide
plate.7) Remove the clamp, and then remove the N−R
lock solenoid.
8) Remove the lock plate B mounting bolt.
9) Remove the lock plate A, B, C and bushing.
(A) Grip
(B) Indicator cover
(C) Indicator light
(A) Clip
(B) Cover
(A) Clip
(B) Guide plate
CS-00020
( A )
( B )
( C )
CS-00105
(A)
(B)
CS-00021
(A)(A) (B)
(A) Clamp
(B) N−R lock solenoid
(A) Lock plate A
(B) Lock plate B
(C) Bushing
(D) Lock plate C
CS-00352
(B)
(A)
CS-00353
CS-00368
(A)(C)
(D)(C)
(B)
(C)

CS-12
CONTROL SYSTEM
Select Lever
D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to each part. CS-3, AT SELECT LEVER, COMPONENT, Gener-
al Description.>
CAUTION:
Apply grease [SUNCALL] around the axle of lock
plate (Turbo model). Apply grease to only indi-
cated portion.
3) Assemble is in the reverse order of disassembly.
NOTE:
 Refer to “COMPOTNENT” for tightening torque.
tion.>
 Tighten the lock plate bolt uniformly. After installa-
tion, put the base plate upside down, and then push
the lock plate up. Make sure the lock plate falls by its
weight when releasing it. If not, retighten the bolt.
4) After completion of fitting, transfer the select le-
ver to range “P” — “1”, then check the indicator and
select lever are matched, the pointer and position
mark are matched and the operating force.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Cor-
rect or replace if defective.
2) Confirm the following parts for operating condi-
tion before assembly. Moving condition of the se-
lect lever assembly, it should move smoothly.
CS-00355
CS-00356

CS-14
CONTROL SYSTEM
Select Cable
4) Install the snap pin to range select lever.
5) Shift the select lever to “N” range, then adjust the
select cable position. MENT, Select Cable.>
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe.
 Non-turbo model
haust Pipe.>
 Turbo model
Exhaust Pipe.>
C: INSPECTION
Check the removed cable and replace if damaged,
rusty, or defective.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deterio-
ration.
5) Shift the select lever from “P” range to “1” range.
You should be able to feel the detentes in each
range. If the detentes cannot be felt or the range
pointer is improperly aligned, adjust the cable.
D: ADJUSTMENT
1) Set the vehicle on a lift.
2) Shift the select lever to “N” range.
3) Lift-up the vehicle.
4) Remove the rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped)6) Loosen the adjusting nuts on each side.
7) Turn the adjusting nut B until it lightly touches
the bushing assembly.
8) While preventing the adjusting nut B from mov-
ing with a wrench, tighten the adjusting nut A.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
CS-00036
(C)(B) (A)
(E) (D)
(A) Adjusting nut A
(B) Adjusting nut B
(A) Front side
(B) Select lever
(C) Bushing ASSY
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
(A) Adjusting nut A
(B) Adjusting nut B
CS-00040
(A) (B)
CS-00041
(A)(B)
(C)
(D)
(E)(F)
CS-00042
(A)
(B)

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)

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.

4AT-18
AUTOMATIC TRANSMISSION
General Description
C: CAUTION
 Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust and dirt.
 Until the oil pan is installed, do not place with the
inside of oil pan 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 yourself, 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 or ATF 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 ATF 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 vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
 Avoid damaging the mating surface of the case.
 Before applying sealant, completely remove the
old seal.

4AT-32
AUTOMATIC TRANSMISSION
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of the automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st ←→ 2nd ←→ 3rd ←→
4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
kick-down shock level.
5. ENGINE BRAKE OPERATION
 Check the 3rd gear engine brake when shifting
down from D ←→ 3rd range while driving in 4th
gear of D range [50 — 60 km/h (31 — 37 MPH)].
 Check the 2nd gear engine brake when shifting
between 3rd ←→ 2nd range while driving in the 3rd
range of 3rd gear [40 — 50 km/h (25 — 31 MPH)].
 Check the 1st gear engine brake when shifting
between 2nd ←→ 1st range while driving in the 2nd
range of 2nd gear [20 — 30 km/h (12 — 19 MPH)].
6. LOCK-UP FUNCTION
 Check that rpm does not change sharply when
the axle pedal is lightly depressed when driving on
flat roads at 60 km/h (37 MPH).
 Check slip lock-up with following procedure.
Subaru Select Monitor is needed for checking (EC,
EK model).
Before start checking, check that the DTC is not ex-
isted using Subaru Select Monitor. When the DTC
is existed, perform the collective action with DTC
and check that the DTC is not existed again, and
then start the checking.
1) The check performed on flat and straight road or
free roller.
NOTE:
 Slip lock-up does not operate when the vehicle is
lifted up, because of not occurring surface resis-
tance.
 Also checking on the free roller, check with de-
pressing foot brake lightly to make the checking
easier, because the surface resistance will be defi-
cient2) Connect the Subaru Select Monitor.
3) Check ATF temperature using Subaru Select
Monitor.
NOTE:
 ATF temperature is between 50 — 100°C (122
— 212°F).
 When the temperature is low, warm-up the ATF
by running the vehicle or etc.
4) Start the engine, and make the lock-up duty be
able to read on data display of Subaru Select Mon-
itor.
5) 35 — 40 Drive the vehicle at a constant speed of
35 — 40 km/h (22 — 25 MPH).
6) Read the lock-up duty while vehicle is running.
Standard value:
25 — 45%
NOTE:
On the free roller, the value sometimes lowers.
 Slip lock-up control is not operating when the
lock-up duty is less than 5%, or when the lock-up
duty goes down immediately after starts rise. On
these cases, improper ATF or deterioration of ATF
may be the cause. Check the amount of ATF or re-
place them, and then recheck it.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. NOISE AND VIBRATION
Check for unusual sounds and vibration while driv-
ing and during shifting.
9. CLIMBING CONTROL FUNCTION
 Check that the gear remains in 3rd when going
up a grade.
 Check that the gear remains in 3rd when apply-
ing the brakes while going down a grade.
10.TRANSFER CLUTCH
Check tight corner braking when the vehicle started
with steering fully turned.
11.OIL LEAKS
After the driving test, inspect for oil leaks.

4AT-40
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
13) Disconnect the hose from lower portion of ATF
cooler (with warmer function), and then secure the
ATF cooler to vehicle using string, etc.
14) Remove the pitching stopper.
15) Separate the torque converter clutch assembly
from drive plate.
(1) Remove the service hole plug.
(2) Remove the bolts which hold torque con-
verter clutch assembly to drive plate.
(3) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
CAUTION:
Be careful not to drop bolts into torque convert-
er clutch housing.16) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
17) Remove the ATF level gauge.
CAUTION:
Plug the opening to prevent entering foreign
particles into transmission fluid.
18) Set ST.
ST 41099AC000 ENGINE SUPPORT ASSEM-
BLY
19) Remove the bolts which hold right upper side of
transmission to engine.
AT-02118
AT-00023
AT-00102
AT-00804
ST
AT-00680
AT-00105
ST
AT-00106