2004 SUBARU FORESTER replace disc

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)-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

4AT(H4DOTC)-125
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
3 CHECK KICK-DOWN SWITCH GROUND
LINE.
1) Disconnect the connector from kick-down
switch.
2) Measure the resistance of harness connector
between kick-down switch and chassis ground.
Connector & terminal
(B129) No. 1 — Chassis ground:Is the resistance less than 1
Ω?Go to step 4.Repair the open cir-
cuit in harness
between kick-down
switch and TCM.
4 CHECK KICK-DOWN SWITCH.
Measure the resistance for kick-down switch
when depressing the accelerator pedal.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Go to step 5.Replace the kick-
down switch. to SP(H4SO)-4,
Accelerator
Pedal.>
5 CHECK KICK-DOWN SWITCH.
Measure the resistance for kick-down switch
when pressing the accelerator pedal.
Te r m i n a l s
No. 1 — No. 2:Is the resistance more than 1
MΩ?Go to step 6.Replace the kick-
down switch.
6 CHECK HARNESS CONNECTOR BETWEEN
TCM AND KICK-DOWN SWITCH.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from kick-down
switch.
3) Measure the resistance of harness connec-
tor between TCM and kick-down switch.
Connector & terminal
(B54) No. 11 — (B129) No. 2:Is the resistance less than 1
Ω?Go to step 7.Repair the open
circuit in harness
between TCM and
kick-down switch.
7 CHECK HARNESS CONNECTOR BETWEEN
TCM AND KICK-DOWN SWITCH.
Measure the resistance of harness connector
between TCM connector and chassis ground.
Connector & terminal
(B54) No. 11 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 8.Repair the short
circuit in harness
between TCM and
chassis ground.
8 CHECK INPUT SIGNAL FOR TCM.
1) Turn the ignition switch to OFF.
2) Connect the connector to kick-down switch.
3) Turn the ignition switch to ON (engine OFF).
4) Measure the signal voltage for TCM when
not depressing the accelerator pedal.
Connector & terminal
(B55) No. 11 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 9.Go to step 10.
9 CHECK INPUT SIGNAL FOR TCM.
Measure the signal voltage for TCM when press-
ing the accelerator pedal.
Connector & terminal
(B55) No. 11 (+) — Chassis ground (
−):Is the voltage more than 6.5 V? A temporary poor
contact of the con-
nector and har-
ness may be the
cause. Repair the
harness and con-
nector in TCM.Go to step 10.
10 CHECK POOR CONTACT.Is there poor contact? Repair the poor
contact.Replace the TCM.
Transmission Con-
trol Module
(TCM).> Step Check Yes No

5MT-32
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
3. Manual Transmission As-
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Drain the transmission gear oil completely. to 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
4) Open the front hood fully, and support with stay.
5) Remove the air intake duct and air cleaner case.
(Non-turbo model) AL, Air Intake Duct.> MOVAL, Air Cleaner Case.>
6) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the intercooler. (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>
8) Disconnect the following connectors and trans-
mission cable.
(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
 Non-turbo model Turbo model
(4) Vehicle speed sensor
9) Remove the snap pin and pin from drive select
cable.
10) Remove the drive select cable on transmission.
(Dual-range model)
11) Remove the starter. MOVAL, Starter.>
ME-00062
MT-00063
(A) Snap pin
(B) Clevis pin
(C) Drive select cable
MT-00064
MT-00065
MT-00066
(A)
(B)
(C)

5MT-45
MANUAL TRANSMISSION AND DIFFERENTIAL
Switches and Harness
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch. SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model:
Turbo model:
 Non-turbo model
 Turbo model
4) Replace defective parts.
3. HIGH-LOW SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
4) Replace the defective parts.
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3Less than 1 Ω
Other positions More than 1 MΩ
MT-00110
1 2
MT-00111
1 2
3 4
Gear shift position Terminal No. Specified resistance
LO position
1 and 2Less than 1 Ω
HIGH position More than 1 MΩ
MT-00112
1 2

5MT-46
MANUAL TRANSMISSION AND DIFFERENTIAL
Vehicle Speed Sensor
8. Vehicle Speed Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Remove the front, center and rear exhaust pipe
and muffler.
4) Disconnect the connector from vehicle speed
sensor.
5) Turn and remove the vehicle speed sensor.
B: INSTALLATION
NOTE:
 Discard the vehicle speed sensor and after re-
moval, replace with a new one.
 Ensure the sensor mounting hole is clean and
free of foreign matter.
 Align the tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tool.
Tightening torque:
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front and center exhaust pipe.
5) Lower the vehicle.
6) Connect the battery ground cable to battery.
C: INSPECTION
Inspect the vehicle speed sensor.
SPEED SENSOR CIRCUIT LOW INPUT, Diagnos-
tic Procedure with Diagnostic Trouble Code
(DTC).> HICLE SPEED SENSOR CIRCUIT HIGH INPUT,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
MT-00113

5MT-92
MANUAL TRANSMISSION AND DIFFERENTIAL
Drive Pinion Shaft Assembly
11) Install the washer using ST1, ST2 and press.
NOTE:
 Discard the old lock nuts, replace with new ones.
 Secure the lock nut in four places.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
12) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.13) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because the spacer must be installed in
proper direction.
(A) Washer
MT-00261
(A)
ST1
ST2
MT-00262
(A) Driven shaft
(B) Drive pinion shaft
(C) Drive pinion collar
(D) Needle bearing (25×30×20)
(E) Adjusting washer No. 2 (25×36×4)
(F) Thrust bearing (25×37.5×3)
(G) Adjusting washer No. 1 (25×36×t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)

CL-17
CLUTCH SYSTEM
Clutch Disc and Cover
C: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of
facing. Replace if facings are worn locally or worn
down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any cleaning fluid.
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace the clutch disc and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other points for oil
leakage.4) Run out on facing
If run out exceeds the specified value at the outer
circumference of facing, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
Limit for run out:
2.0 L Non-Turbo model and LHD 2.5 L Non-
Turbo model:
0.8 (0.031 in) mm at R = 110 mm (4.33 in)
Turbo model and RHD 2.5 L Non-Turbo mod-
el:
1.0 (0.039 in) mm at R = 110 mm (4.33 in)
5) Worn spline, loose rivets and torsion spring fail-
ure.
Replace defective parts.
(A) Clutch facing
CL-00014
CL-00015
(A)
(A) Spline
(B) Rivet
(C) Torsion spring
CL-00016
ST
CL-00017