2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

TRANSMISSION SECTION

CONTROL SYSTEM CS

AUTOMATIC TRANSMISSION 4AT

AUTOMATIC TRANSMISSION 4AT(H4SO)

(DIAGNOSTIC)

AUTOMATIC TRANSMISSION 4AT(H4DOTC)

(DIAGNOSTIC)
This service manual has been prepared
to provide SUBARU service personnel AUTOMATIC TRANSMISSION 4AT(H4DOTC 2.5)
with the necessary information and data (DIAGNOSTIC)
for the correct maintenance and repair
of SUBARU vehicles. MANUAL TRANSMISSION AND 5MT
This manual includes the procedures DIFFERENTIAL
for maintenance, disassembling, reas-
sembling, inspection and adjustment of CLUTCH SYSTEM CL
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.

FUJI HEAVY INDUSTRIES LTD. G8080GE5

CONTROL SYSTEM

CS
Page
1. General Description ....................................................................................2
2. Select Lever ................................................................................................8
3. Select Cable..............................................................................................13
4. N-R Lock Solenoid ....................................................................................16
5. MT Gear Shift Lever..................................................................................17
6. MT Drive Select Lever...............................................................................23
7. Drive Select Cable ....................................................................................25
8. General Diagnostic Table..........................................................................26
 General Description
CONTROL SYSTEM

1. General Description
A: SPECIFICATION
Item Specification
Swing torque of rod against lever N (kgf, Ib) 3.7 (0.38, 0.83) or less

CS-2
 General Description
CONTROL SYSTEM

B: COMPONENT
1. AT SELECT LEVER
• NON-TURBO MODEL

(2)
(12)
(4) (24)

(3) (5) (13)

T2 (23)
(22)
(1)

(6) (14)

(15)
(8) (7)
(22)
(9)
(16)

(10)
(11)
T3
(17)
(18)

(19)

T1

T3 (20)
(21)

CS-00367

(1) Bulb (11) Spacer (21) Adjusting nut A

(2) Detent arm (12) Grip (22) Clip
(3) Detent spring (13) Indicator cover (23) Tube
(4) Select lever ASSY (14) Blind (24) Cover
(5) Spring pin (15) Cushion
(6) Arm ASSY (16) Guide plate Tightening torque: N·m (kgf-m, ft-lb)
(7) Bushing ASSY (17) Snap pin T1: 7.5 (0.76, 5.5)
(8) Base plate (18) Washer T2: 13 (1.3, 9.4)
(9) Grommet (19) Select cable T3: 18 (1.8, 13.0)
(10) Packing (20) Adjusting nut B

CS-3
 General Description
CONTROL SYSTEM

• TURBO MODEL

(7)

(8) (10) (1)

(9)

(33) (3)
(32)
(15)
(2)
(16) (18)
(17) (12)
(13)

(14) (11)

T3 (4)

T1
(20)
(19)
(21)
(5)

(23) (22)
(20) (24)

(25)

(6)
(28)
(26)
(27) T4

(29)
(31)

T2
T4 (30)
CS-00366

(1) Grip (14) Lock plate A (27) Washer

(2) Indicator cover (15) Bushing (28) Snap pin
(3) Cover (16) Lock plate C (29) Select cable
(4) Blind (17) N−R lock solenoid (30) Adjusting nut B
(5) Cushion (18) Clamp (31) Adjusting nut A
(6) Guide plate (19) Bulb (32) Cover
(7) Detent arm (20) Clip (33) Clip
(8) Detent spring (21) Arm ASSY
(9) Tube (22) Bushing ASSY Tightening torque: N·m (kgf-m, ft-lb)
(10) Select lever ASSY (23) Base plate ASSY T1: 2.0 (0.2, 1.4)
(11) Lock plate B (24) Grommet T2: 7.5 (0.76, 5.5)
(12) Bushing (25) Packing T3: 13 (1.3, 9.4)
(13) Bushing (26) Spacer T4: 18 (1.8, 13.0)

CS-4
 General Description
CONTROL SYSTEM

2. MT GEAR SHIFT LEVER

(1)
(22)

(2)
(23)

(5)

(12) T3

(16) T2 T1
(15)
(21)
(5) (4)

(5)

(11)

(3)
(20) (12)
(5)
(10)
(14)
(8)

(17)
(7)

(6)
(18)
T3
(10)
T3 (19) (13)
(9)

T3
CS-00357

(1) Gear shift knob (11) Bushing A (21) Boot & insulator ASSY
(2) Console boot (12) Spring pin (22) Front cover
(3) Plate ASSY (13) Cushion rubber (23) Clamp
(4) Gear shift lever (14) Bushing B
(5) Bushing (15) Joint Tightening torque: N·m (kgf-m, ft-lb)
(6) Bushing (16) Rod T1: 7.5 (0.76, 5.5)
(7) Lock wire (17) Bracket T2: 12 (1.2, 8.7)
(8) Boot (18) Washer T3: 18 (1.8, 13.0)
(9) Snap ring (19) Stay
(10) O-ring (20) Spacer

CS-5
 General Description
CONTROL SYSTEM

3. DRIVE SELECT LEVER

(1)

T2
T1
(4)
(3)

(2)
(10)

(7)
(6)
(9)

(5)

(8)

T2

CS-00004

(1) Knob (6) Spring Tightening torque: N·m (kgf-m, ft-lb)

(2) Cushion (7) Lever ASSY T1: 1.6 (0.16, 1.2)
(3) Plate ASSY (8) Clip T2: 18 (1.8, 13.0)
(4) Bushing (9) Clevis pin
(5) Cable (10) Snap pin

CS-6
 General Description
CONTROL SYSTEM

C: CAUTION
• Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
• Use SUBARU genuine fluid, grease etc. or the
equivalent. Do not mix grease etc. with that of an-
other 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 grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
• Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or cloth between the part and vise.
• Before disconnecting electrical connectors, be
sure to disconnect the ground cable from battery.

CS-7
 Select Lever
CONTROL SYSTEM

2. Select Lever B: INSTALLATION

1) Mount the select lever onto vehicle body.
A: REMOVAL 2) Tighten the four bolts to install the select lever to
1) Set the vehicle on a lift. vehicle body, then connect the connector.
2) Disconnect the ground cable from battery.
3) Shift the select lever to “N” range. Tightening torque:
4) Lift-up the vehicle. 13 N·m (1.3 kgf-m, 9.4 ft-lb)
5) Remove the rear exhaust pipe and muffler.
• Non-turbo model
<Ref. to EX(H4SO)-11, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H4SO)-13, REMOVAL, Muf-
fler.>
• Turbo model
<Ref. to EX(H4DOTC)-14, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-16, REMOV-
AL, Muffler.>
6) Remove the heat shield cover. (If equipped)
CS-00168
7) Disconnect the cable from select lever, and then
remove the cable bracket. 3) Install the console box. <Ref. to EI-39, INSTAL-
LATION, Console Box.>
4) Shift the select lever to “N” range.
5) Lift-up the vehicle.
6) Shift the range select lever to “N” range.
7) Insert the thread portion of inner cable into con-
nector hole of the select lever, and fix the outer ca-
ble end to bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(B) (A)
CS-00017 8) Adjust the select cable position. <Ref. to CS-14,
ADJUSTMENT, Select Cable.>
(A) Adjusting nut 9) After completion of fitting, make sure the select
(B) Cable bracket lever operates smoothly all across the operating
range.
8) Lower the vehicle. 10) Install the heat shield cover. (If equipped)
9) Remove the console box. <Ref. to EI-39, RE- 11) Install the rear exhaust pipe and muffler.
MOVAL, Console Box.> • Non-turbo model
10) Disconnect the connectors, then remove the <Ref. to EX(H4SO)-11, INSTALLATION, Rear Ex-
four bolts to take out the select lever assembly from haust Pipe.> <Ref. to EX(H4SO)-13, INSTALLA-
body. TION, Muffler.>
• Turbo model
<Ref. to EX(H4DOTC)-14, INSTALLATION, Rear
Exhaust Pipe.> <Ref. to EX(H4DOTC)-16, IN-
STALLATION, Muffler.>
12) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
and inhibitor switch. <Ref. to CS-14, ADJUST-
MENT, Select Cable.> <Ref. to 4AT-52, ADJUST-
MENT, Inhibitor Switch.>
CS-00018
(1) The engine starts operating when select le-
ver is in “P” range, but not in other ranges.
(2) The back-up light is lit when the select lever
is in “R” range, but not in other ranges.
(3) Select lever and indicator ranges are matched.

CS-8
 Select Lever
CONTROL SYSTEM

C: DISASSEMBLY 5) Remove the grommet, and then extract the

spring pin.
1. NON-TURBO MODEL
1) Remove the grip.
2) Remove the indicator light, and then remove the (A)
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.

(A)
(B)
CS-00027
(B)
(A) Spring pin
(C) (B) Arm ASSY

6) Remove the arm assembly, and then take away

the select lever assembly from base plate.

CS-00020
(B)
(A) Grip
(B) Indicator cover
(C)
(C) Indicator light (A)

3) Remove the blind.

4) Remove the clips, and then remove the guide
plate.
CS-00109

(B) (A) Arm ASSY

(A)
(B) Select lever ASSY
(C) Base plate

(A)

CS-00021

(A) Clip
(B) Guide plate

CS-9
 Select Lever
CONTROL SYSTEM

2. TURBO MODEL 7) Remove the clamp, and then remove the N−R
lock solenoid.
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- (B)
moval.

(A)

(A)
(B) CS-00352

(A) Clamp
(C)
(B) N−R lock solenoid

8) Remove the lock plate B mounting bolt.

CS-00020

(A) Grip
(B) Indicator cover
(C) Indicator light

4) Remove the blind.

5) Remove the cover.
CS-00353

9) Remove the lock plate A, B, C and bushing.

(A) (B) (C) (C)

(B) (C)
(A)
CS-00105

(A) Clip
(B) Cover (D)
CS-00368

6) Remove the clips, and then remove the guide (A) Lock plate A
plate. (B) Lock plate B
(C) Bushing
(B) (D) Lock plate C
(A)

(A)

CS-00021

(A) Clip
(B) Guide plate

CS-10
 Select Lever
CONTROL SYSTEM

10) Remove the cushion plate. 13) Remove the detent spring, and then remove
the detent arm.

(A)

CS-00093 (B)
CS-00110
11) Remove the grommet, and then extract spring
pin.
(A) Detent arm
(B) Detent spring

(A)

(B)
CS-00027

(A) Spring pin

(B) Arm ASSY

12) Remove the arm assembly, and then take

away the select lever assembly from base plate.

(B)

(C)
(A)

CS-00109

(A) Arm ASSY

(B) Select lever ASSY
(C) Base plate

CS-11
 Select Lever
CONTROL SYSTEM

D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to each part. <Ref. to
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.

CS-00355

3) Assemble is in the reverse order of disassembly.

NOTE:
• Refer to “COMPOTNENT” for tightening torque.
<Ref. to CS-3, COMPONENT, General Descrip-
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.

CS-00356

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-12
 Select Cable
CONTROL SYSTEM

3. Select Cable 9) Disconnect the select cable from range select le-
ver, and then remove the cable bracket.
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Prior to removal, shift the select lever to “N”
range.
4) Lift-up the vehicle.
5) Remove the front and center exhaust pipe.
• Non-turbo model
<Ref. to EX(H4SO)-7, REMOVAL, Front Exhaust
Pipe.> (B) (A)
CS-00017
• Turbo model
<Ref. to EX(H4DOTC)-9, REMOVAL, Center Ex- (A) Adjusting nut
haust Pipe.>
(B) Cable bracket
6) Remove the heat shield cover. (If equipped)
7) Remove the snap pin from range select lever. 10) Remove the select cable from plate assembly.
B: INSTALLATION
(D) (A) 1) Install the select cable to plate assembly.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(B) 2) Install the select cable to range select lever.
3) Install the plate assembly to transmission.
(C) (E)
Tightening torque:
T: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
CS-00036

(A) Range select lever

(A)
(B) Snap pin
(C) Select cable T

(D) Clamp
(E) Washer

8) Remove the plate assembly from transmission

case.
(B)
CS-00039

(A) (A) Select cable

(C)
(B) Plate ASSY

(B)
CS-00037

(A) Select cable

(B) Plate ASSY
(C) Clamp

CS-13
 Select Cable
CONTROL SYSTEM

4) Install the snap pin to range select lever. 6) Loosen the adjusting nuts on each side.

(D) (A)

(B)

(C) (E)

(B) (A)
CS-00036 CS-00040

(A) Range select lever (A) Adjusting nut A

(B) Snap pin (B) Adjusting nut B
(C) Select cable
7) Turn the adjusting nut B until it lightly touches
(D) Clamp
the bushing assembly.
(E) Washer
(B)
5) Shift the select lever to “N” range, then adjust the
select cable position. <Ref. to CS-14, ADJUST-
MENT, Select Cable.> (C)
(A)
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe.
• Non-turbo model
<Ref. to EX(H4SO)-8, INSTALLATION, Front Ex-
haust Pipe.> (D) (F)
• Turbo model (E) CS-00041
<Ref. to EX(H4DOTC)-10, INSTALLATION, Center
Exhaust Pipe.> (A) Front side
C: INSPECTION (B) Select lever
Check the removed cable and replace if damaged, (C) Bushing ASSY
rusty, or defective. (D) Adjusting nut B
1) Check for smooth operation of the cable. (E) Contact point
2) Check the inner cable for damage and rust. (F) Adjusting nut A
3) Check the outer cable for damage, bends, and
cracks. 8) While preventing the adjusting nut B from mov-
4) Check the boot for damage, cracks, and deterio- ing with a wrench, tighten the adjusting nut A.
ration. Tightening torque:
5) Shift the select lever from “P” range to “1” range. 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
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. (A)
(B)
4) Remove the rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped)
CS-00042

(A) Adjusting nut A

(B) Adjusting nut B

CS-14
 Select Cable
CONTROL SYSTEM

9) After completion of fitting, make sure that the se-

lect lever operates smoothly all across the operat-
ing range.
10) Install in the reverse order of removal.

CS-15
 N-R Lock Solenoid
CONTROL SYSTEM

4. N-R Lock Solenoid 8) Remove the cover.

A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the console box. <Ref. to EI-39, RE-
(A)
MOVAL, Console Box.>
3) Disconnect the connector.
4) Remove the grip.
5) Remove the indicator bulb from indicator cover.
(B)

CS-00105

(A) Clip
(B) Cover

9) Remove the clamp and remove the N−R lock so-

lenoid.

CS-00043

6) Remove the indicator cover.

(B)

(A)
CS-00352

(A) Clamp
(B) N−R lock solenoid
CS-00095

7) Remove the slider.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Step Check Yes No
1 CHECK N−R LOCK SOLENOID. Is the resistance 20 — 40 Ω? Go to step 2. Replace the N−R
Measure the resistance of N−R lock solenoid lock solenoid.
connector terminals.
Terminal
No. 4 — No. 5
2 CHECK N−R LOCK SOLENOID. Is the N−R lock solenoid oper- Normal Replace the N−R
Connect the battery with N−R lock solenoid ating properly? lock solenoid.
connector terminal, and operate the solenoid.
Terminal
No. 4 (+) — No. 5 (−)

CS-16
 MT Gear Shift Lever
CONTROL SYSTEM

5. MT Gear Shift Lever • Non-turbo model

<Ref. to EX(H4SO)-11, REMOVAL, Rear Exhaust
A: REMOVAL Pipe.> <Ref. to EX(H4SO)-13, REMOVAL, Muf-
1) Set the vehicle on a lift. fler.>
2) Remove the gear shift knob. • Turbo model
3) Disconnect the ground cable from battery. <Ref. to EX(H4DOTC)-14, REMOVAL, Rear Ex-
4) Remove the console box. <Ref. to EI-39, RE- haust Pipe.> <Ref. to EX(H4DOTC)-16, REMOV-
MOVAL, Console Box.> AL, Muffler.>
5) Remove the clamp. 11) Remove the heat shield cover. (If equipped)
12) Remove the stay from transmission bracket.

(A)

CS-00099 (B)

CS-00050
6) Remove the boot & insulator assembly.
(A) Stay
(B) Transmission bracket

13) Remove the rod from joint.

(A)

(B)
CS-00100

7) Remove the drive select cable. <Ref. to CS-25,

REMOVAL, Drive Select Cable.>
8) Remove the plate assembly from body.
CS-00051

(A) Stay
(B) Rod

14) Remove the cushion rubber from body.

(A)

CS-00101

9) Lift-up the vehicle.

10) Remove the rear exhaust pipe and muffler. (B)

CS-00052

(A) Stay
(B) Cushion rubber

CS-17
 MT Gear Shift Lever
CONTROL SYSTEM

15) Remove the spring pin, and then extract the 3) Install the joint to transmission and secure with
joint. the spring pin.

(A) (A)

(B) (B)

CS-00053 CS-00053

(A) Joint (A) Joint

(B) Spring pin (B) Spring pin

16) Lower the vehicle. 4) Mount the cushion rubber on the body.
17) Remove the gear shift lever.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)

(A)

(B)

CS-00054

B: INSTALLATION CS-00052
1) Insert the gear shift lever from room side.
(A) Stay
NOTE:
(B) Cushion rubber
After inserting the rod and stay, temporarily put them
onto transmission mount. 5) Connect the rod to the joint.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)

(A)

(B)

CS-00054

2) Lift-up the vehicle.

CS-00051

(A) Stay
(B) Rod

CS-18
 MT Gear Shift Lever
CONTROL SYSTEM

6) Connect the stay to transmission bracket. 12) Install the boot and insulator assembly to the
vehicle in proper direction.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)

(A)

CS-00100
(B)

CS-00050
13) Install the clamp.
14) Install the console box. <Ref. to EI-39, INSTAL-
(A) Stay LATION, Console Box.>
(B) Transmission bracket C: DISASSEMBLY
7) Install the heat shield cover. (If equipped) 1) Remove the lock wire.
8) Install the rear exhaust pipe and muffler.
• Non-turbo model
<Ref. to EX(H4SO)-11, INSTALLATION, Rear Ex-
haust Pipe.> <Ref. to EX(H4SO)-13, INSTALLA-
TION, Muffler.>
• Turbo model
<Ref. to EX(H4DOTC)-14, INSTALLATION, Rear (B)
Exhaust Pipe.> <Ref. to EX(H4DOTC)-16, IN- (A)
STALLATION, Muffler.>
9) Lower the vehicle. CS-00055
10) Install the plate assembly to body.
Tightening torque: (A) Lock wire
7.5 N·m (0.76 kgf-m, 5.5 ft-lb) (B) Stay

2) Remove the rod from gear shift lever.

(A)

(B)

CS-00101
(C)
11) Install the drive select cable. <Ref. to CS-25, CS-00056
INSTALLATION, Drive Select Cable.>
(A) Rod
(B) Gear shift lever
(C) Stay

CS-19
 MT Gear Shift Lever
CONTROL SYSTEM

3) Remove the snap ring from bushing B, and then 7) Draw out the spring pin, and then remove the
disconnect the stay. bushing A from gear shift lever.

(B)

(A)

(B)
(A)
(C)

CS-00057 CS-00060

(A) Snap ring (A) Spring pin

(B) Bushing B (B) Bushing A
(C) Stay
D: ASSEMBLY
4) Remove the boot from gear shift lever. 1) Clean all parts before assembly.
5) Remove the bushing and cushion rubber from 2) Mount the bushing and cushion rubber on the
stay. stay.
(A) (A)

(B)

(C) (B)

CS-00058 CS-00061

(A) Bushing (A) Bushing

(B) Stay (B) Cushion rubber
(C) Cushion rubber

6) Remove the O-ring, and then remove the bush-

ing B.

(C)

(B)

(A)
CS-00059

(A) O-ring
(B) O-ring
(C) Bushing B

CS-20
 MT Gear Shift Lever
CONTROL SYSTEM

3) Mount each part; boot, O-ring, bushing A, spac- 6) Tighten with a lock wire to the extent that the
er, bushing B, bushing and spring pin on the gear boot will not come off.
shift lever. NOTE:
NOTE: Always use new lock wire.
• 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.

(C) (B)
(D) (A)
(E)
(G)
(F) CS-00055
(H)
(B) (A) Lock wire
(A) (B) Stay
CS-00062
7) Insert the rod into boot hole.
(A) Boot 8) Connect the rod to gear shift lever.
(B) O-ring Tightening torque:
(C) Bushing 12 N·m (1.2 kgf-m, 8.7 ft-lb)
(D) Spacer
(E) Bushing A
(F) Bushing B
(A)
(G) Spring pin
(H) O-ring (B)

4) Insert the gear shift lever into boot hole.

5) Install the snap ring and stay to bushing B.

(C)
(B) CS-00056

(A) Rod
(B) Gear shift lever
(A)
(C) Stay

CS-00165

(A) Snap ring

(B) Bushing B

CS-21
 MT Gear Shift Lever
CONTROL SYSTEM

E: INSPECTION 3) Check that there is no excessive play and that

1) Check each part (bushing, cushion rubber, spacer, parts move smoothly.
boot, stay, rod, etc.) for deformation, damage and
wear. Repair or replace any defective part. Determine
defective parts by comparing with new parts.

(A)

(F)

(A)

(C)
(D)

(B)

(E)

CS-00064

(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod

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 less

(A)
(B)

CS-00065

(A) Center of rotation

(B) Swing torque

CS-22
 MT Drive Select Lever
CONTROL SYSTEM

6. MT Drive Select Lever B: INSTALLATION

1) Install the drive select cable to lever assembly,
A: REMOVAL and then fasten it with a clip.
1) Apply parking brake and place chocks to hold
wheels.
(B)
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. <Ref. to EI-39, RE-
MOVAL, Console Box.>
6) Remove the bolt installing drive select lever as- (A)
sembly on body.
(C)
CS-00067

(A) Flange nut

(B) Lever ASSY
(C) Clip

2) Install the drive select lever.

Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CS-00102
3) Shift the drive select lever to HI position.
7) Remove the flange nut and clip, and then dis-
connect the cable from lever assembly.

(B) (A)

(A)
CS-00068
(C)
CS-00067 (A) HI position

(A) Flange nut 4) Insert the cable eye end bolt into lever arm slit.
(B) Lever ASSY
(C) Clip

(A) (B)

CS-00069

(A) Cable eye end bolt

(B) Lever arm

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)

CS-23
 MT Drive Select Lever
CONTROL SYSTEM

6) Install in the reverse order of removal.

C: DISASSEMBLY
1) Remove the spring.

(A)

CS-00070

(A) Spring

2) Remove the lever, cushion and bushing.

(B) (A)
(C)

(D)

(E)

CS-00071

(A) Washer
(B) Bushing
(C) Plate ASSY
(D) Cushion
(E) Lever ASSY

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.

CS-24
 Drive Select Cable
CONTROL SYSTEM

7. Drive Select Cable D: ADJUSTMENT

1) Shift the drive select lever to HI position.
A: REMOVAL 2) Remove the drive select lever knob.
1) Remove the drive select lever. <Ref. to CS-23, 3) Remove the console box. <Ref. to EI-39, RE-
REMOVAL, MT Drive Select Lever.> MOVAL, Console Box.>
2) Remove the intake duct. <Ref. to IN(H4SO)-7, 4) Remove the nut.
REMOVAL, Air Intake Duct.>
3) Remove the air cleaner case. <Ref. to IN(H4SO)-
6, REMOVAL, Air Cleaner Case.>
4) Remove the snap pin and clevis pin.
5) Loosen the nut and disconnect the cable from
cable bracket.

(C)

CS-00104

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
(B)
bolt stops naturally.
(A)
CS-00103 Tightening torque:
18 N·m (1. 8 kgf-m, 13.0 ft-lb)
(A) Snap pin
(B) Clevis pin
(C) Nut

6) Disconnect the cable from transmission clamp.

7) Remove the cable from the under side of vehi-
cle.

CS-00104

7) Shift the transmission to HI or LO position by

moving the drive select lever. If it does not move,
readjust the cable.

CS-00073

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. <Ref. to CS-25, ADJUSTMENT,
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.

CS-25
 General Diagnostic Table
CONTROL SYSTEM

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.

CS-26