2004 SUBARU FORESTER length

4AT(H4DOTC)-20
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Clear Memory Mode
9. Clear Memory Mode
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
Current DTC shown on display are cleared by turn-
ing the ignition switch to OFF after conducting on-
board diagnostics operation. Previous DTC, how-
ever, cannot be cleared since they are stored in the
TCM memory which is operating on back-up power
supply. These DTC can be cleared by removing the
TCM connector for at least two minutes.
CLEAR MEMORY:
Disconnect the TCM connector (B55). (for at
least two minutes)
 The TCM connector (B55) is located in the line to
memory back-up power supply of TCM. Removal of
this connector clears the previous DTC stored in
TCM memory.
 Be sure to remove the TCM connector (B55) for
at least the specified length of time. Otherwise, the
DTC may not be cleared.
2. WITH SUBARU SELECT MONITOR
Refer to “Subaru Select Monitor” for information
about how to clear DTC.
MODE, OPERATION, Subaru Select Monitor.>

5MT-86
MANUAL TRANSMISSION AND DIFFERENTIAL
Input Shaft Assembly
3) Gears
 Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
 Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
 Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
 When the inner surface and end face are dam-
aged.
 When the ring inner surface is excessively or
partially worn down.
 When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
Clearance:
0 — 0.12 mm (0 — 0.0047 in)
If the measurement is not within specification, se-
lect a suitable snap ring.F: ADJUSTMENT
1) Place transmission main shaft assembly and in-
put shaft on transmission main case without shim.
2) The proper number of shim can be determined
as follows:
D = A−(B+C)
A: Main case length (353 mm (13.90 in)
B: Input shaft complete length
C: Main shaft assembly length
NOTE:
The thickness of shim is 0.45 to 0.55 mm (0.0177 to
0.0217 in).
(A) Snap ring
Snap ring
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
MT-00239
(A)
Dimension “D” mm (in) Number of shims
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
MT-01015
CB

CL-37
CLUTCH SYSTEM
Clutch Pedal
5) Remove the following parts (B to H) from clutch
pedal bracket (A) as shown in the figure.
6) Remove the spacer, bushing and pedal pad from
clutch pedal.
D: ASSEMBLY
1) Attach the stopper, etc. to pedal bracket tempo-
rarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach the brake pedal return spring,
assist rods, spring, and bushing.
NOTE:
Clean up inside of bushings and apply grease be-
fore installing the spacer.
4) Install the hill holder cable to clutch pedal.
E: INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approx. 10 N (1 kgf, 2 lb) to ensure
pedal deflection is in specified range.
NOTE:
If excessive deflection is noted, replace the bush-
ings with new ones.
Deflection of clutch pedal:
Service limit
2.0 mm (0.079 in) or less
F: ADJUSTMENT
1. LHD MODEL
1) Measure the full stroke amount of clutch pedal.
NOTE:
 Measure the length between seat cushion front
end and center portion of clutch pedal.
 Slide the seat at seventh notch from first notch.
Specified clutch pedal full stroke: A
130 — 135 mm (5.12 — 5.31 in)
(A) Clutch pedal bracket
(B) Bushing C
(C) Clip
(D) O-ring
(E) Bushing S
(F) Spring S
(G) Rod S
(H) Bushing
(A) Spacer
(B) Bushing
(C) Bushing
(D) Pedal pad
(E) Clutch pedal
(F) Bushing C
( A )
( B )
( C )
( D )
( E )
( F )( G )
( H )
CL-00129
( A )
( B )
( B )
( C )
( D )
( E )
( F )
( F )
CL-00130
(A) Clutch pedal
(B) Brake pedal
(A) Clutch (Full stroke condition)
(B) Scale
(C) Seat
CL-00098
CL-00078(A)(B)(C)A

CL-38
CLUTCH SYSTEM
Clutch Pedal
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nut.
4) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.5) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
 Model without cruise control
 Model with cruise control
6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
7) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)
(A) Stopper
(B) Stopper bolt
(A) Clutch switch
(B) Stopper
(C) Clearance
(A) Accelerator pedal
(B) Clevis
(A)
(B)
CL-00131
(A)
(B) (C)
CL-00132
CL-00101
(B)
(A)

CL-39
CLUTCH SYSTEM
Clutch Pedal
9) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
10) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
130 — 135 mm (5.12 — 5.31 in)
11) Install the clutch switch. STALLATION, Clutch Switch.>
2. RHD MODEL
1) Measure the full stroke amount of clutch pedal.
NOTE:
 Measure the length between seat cushion front
end and center portion of clutch pedal.
 Slide the seat at seventh notch from first notch.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) If the stroke amount can not be adjusted by stop-
per nut, remove the clutch switch. REMOVAL, Clutch Switch.>4) Loosen the push rod lock nut.
5) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.
(A) Clutch (Full stroke condition)
(B) Scale
(C) Seat
CL-00078(A)(B)(C)A
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)

CL-40
CLUTCH SYSTEM
Clutch Pedal
6) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
7) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
8) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
9) Move the clevis pin in lateral direction to ensure
it moves smoothly.
10) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
11) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
12) Install the clutch switch. STALLATION, Clutch Switch.>
(A) Stopper bolt
(A) Clutch pedal
(B) Brake pedal
CL-00134
(A)
CL-00085
(A)
(B)