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It may seem obvious, but the first step in the job is to disconnect the battery after recording the customer’s radio station presets. Even a manual transmission has a surprising number of wires attached to and surrounding it. Why take the chance of damaging anything due to an accidental short circuit? Remove the resin ‘pitching stopper’ and its bracket on the transmission. This step is necessary for the engine and transmission to drop far enough to clear the firewall during transmission removal. A special tool (P/N 927670000) is available to support the engine once the transmission has been removed, but you can replace the clutch without this aid. Many manual transmission Subaru vehicles are also equipped with the Hill- Holder system. This system lets the driver remove his right foot from the brake pedal after applying the brakes to stop on an incline of more than three degrees. This prevents ‘rollback’ when engaging the clutch to move the vehicle forward on a hill. The Hill-Holder cable shown here below the conventional clutch cable links the clutch pedal to the Hill-Holder pressure hold valve (PHV). Loosen both cables and remove their bracket from the transmission. Several electrical connectors are located at the top right side of the transmission (neutral position switch, back-up light switch, speed sensor, etc.). The connectors are color-coded, so it’s a simple matter to disconnect them and move them aside. Also remove the upper transmission mounting bolts, assorted brackets, main battery ground cable and the starter motor at this time. This transmission ground cable can easily escape notice. The other end of the cable is unreachable from above the transmission. A transmission case bolt must be removed to remove the ground wire at the transmission, so removing it at the body makes more sense to avoid the risk of a leak. Position the cable out of the way so it doesn’t snag on anything during transmission removal.

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1. Remove key cylinder. Refer to previous steps. 2. Remove lower steering column cover screws and remove cover. 3. Remove ignition switch mounting screw. Use tamper proof torx bit (Snap-On® SDMTR10 or equivalent) to remove the screw. 4. Using a small screwdriver, push on locking tab and remove switch from steering column. 5. Disconnect two electrical connectors at rear of ignition switch. INSTALLATION 1. 2. 3. 4. Before installing ignition switch, rotate the slot in the switch to the ON position. Connect two electrical connectors to rear of ignition switch. Make sure that locking tabs are fully seated into wiring connectors. Position switch to column and install tamper proof screw. Tighten screw to 3 N.m (26 in. lbs.). Install steering column lower cover.

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Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the shift cable from the manual control lever. 3. Disconnect the digital transmission range (TR) sensor electrical connector. 4. Remove the manual control outer lever nut and manual control outer lever. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E 5. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut.

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Closed Throttle Position Switch F60, Checking Special tools, testers and auxiliary items required Multimeter . Wiring diagram Test procedure Perform a preliminary check to verify the customers complaint. Refer to Check Test requirement The Motronic Engine Control Module (ECM) J220 fuses OK. Battery voltage at least 12.5 volts. All electrical consumers such as, lights and rear window defroster, switched off. Vehicles with automatic transmission, shift selector lever into position “P” or “N” . A/C switched off. Ground (GND) connections between engine/transmission/chassis OK. Note: Use only gold-plated terminals when servicing the electrical harness connector terminals in Closed Throttle Position (CTP) Switch F60 . Test sequence Remove the engine cover with air filter .

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Park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (P, R, N, D, 4, 3, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in “D” position. When the shift lever is in the “M” position (with E-shift main switch for “D” and “M” pressed), “M” in the shift position indicator light will come on and when the shift lever is in the “D” position (with E-shift main switch for “D” and “M” released), “D” in the shift position indicator light will come on. When the shift lever is in the “L” position (with E-shift main switch for 2 and “L” pressed), “L” in the shift position indicator light will come on. When the shift lever is in the “2″ position (with E-shift main switch for “2″ and “L” released), “2″ in the shift position indicator light will come on. When the shift lever is in 4 or “M” position, the ECM prohibits shifting to 5th. See Fig. 87 . Possible causes are: Open or short in Park/Neutral Position (PNP) switch circuit. Faulty PNP switch. Faulty ECM.