SUBARU FORESTER 2004 Service Repair Manual

4AT-39
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
9. Automatic Transmission As-
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Fully open the front hood and support with the
hood stay.
3) Disconnect the ground cable from battery.
4) Remove the resonator chamber. (Non-turbo
model)
<Ref. to IN(H4SO)-8, REMOVAL, Resonator
Chamber.>
5) Remove the air cleaner case or air intake cham-
ber. (Non-turbo model).
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
6) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-10, REMOVAL, Intercool-
er.>
7) Remove the air cleaner case stay. (Non-turbo
model).
8) Disconnect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
9) Remove the starter.
<Ref. to SC(H4SO)-6, REMOVAL, Starter.>10) Remove the harness from bracket. (with ATF
cooler (with warmer function))
11) Disconnect the ATF cooler hoses from pipes of
transmission side, and then remove the oil charger
pipe. (with ATF cooler (with warmer function))
12) Remove the ATF cooler from the transmission
body. (with ATF cooler (with warmer function))
AT-00101
AT-00089
(A) Inlet hose
(B) Outlet hose
AT-01867
AT-01866(A)(B)
AT-01868

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

4AT-41
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Lift-up the vehicle.
21) Remove the under cover.
22) Remove the front, center, rear, exhaust pipes
and muffler. (Non-turbo model).
<Ref. to EX(H4SO)-7, REMOVAL, Front Exhaust
Pipe.> <Ref. to EX(H4SO)-11, REMOVAL, Rear
Exhaust Pipe.> <Ref. to EX(H4SO)-13, REMOV-
AL, Muffler.>
23) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
<Ref. to EX(H4DOTC)-9, REMOVAL, Center Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-14, REMOV-
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-
16, REMOVAL, Muffler.>
24) Remove the heat shield cover. (If equipped)
25) Remove the drain plug (ATF) to drain ATF.
26) Disconnect the ATF cooler hoses from pipes of
transmission side, and remove the ATF level gauge
guide. (without ATF cooler (with warmer function))
27) Remove the propeller shaft.
<Ref. to DS-15, REMOVAL, Propeller Shaft.>
28) Remove the shift select cable.
<Ref. to CS-13, REMOVAL, Select Cable.>29) Disconnect the stabilizer link from the trans-
verse link.
30) Remove the bolt securing ball joint of trans-
verse link to housing.
31) Pull out the front drive shaft from transmission.
(1) Face the letter of “AT” to the transmission
side.
ST 28399SA000 DRIVE SHAFT REMOVER
(A) Oil pan
(B) Drain plug (ATF)
AT-00080
(A)(B)
AT-00683
(A) Letter “AT”
AT-00107
AT-00115
AT-00461
(A)

4AT-42
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(2) Insert ST between the transmission and
front drive shaft.
NOTE:
Set the protrusion portion of ST to the torque con-
verter clutch housing.
ST 28399SA000 DRIVE SHAFT REMOVER
(3) Hold the joint portion of front drive shaft
(AARi) by hand and extract the housing from the
transmission by pressing it outside.
32) Remove the bolts which hold lower side of
transmission to engine.
33) Place the transmission jack under transmis-
sion.
NOTE:
Make sure that the support plates of transmission
jack don’t touch the oil pan.34) Remove the transmission rear crossmember
from the vehicle.
35) Slightly lowering the transmission jack, fully
contract the engine support and tilt the engine
backward.
36) Remove the transmission.
CAUTION:
Remove the transmission and torque converter
as a unit from the engine.
37) Remove the rear cushion rubber from transmis-
sion.
(A) Protrusion portion of ST
(B) Torque converter clutch case
AT-00444
ST
(A)
(B)
AT-00108
AT-00024
AT-00109

4AT-43
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
B: INSTALLATION
1) Replace the differential side oil seal with a new
one. <Ref. to 4AT-50, REPLACEMENT, Differen-
tial Side Retainer Oil Seal.>
2) Install the rear cushion rubber to the transmis-
sion.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
3) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
4) Install the transmission onto the engine.
(1) Lift up the transmission gradually using a
transmission jack.
(2) Engage them at splines.
(3) Slightly raising the transmission jack, turn
the screws of engine support and tilt the engine
forward.5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
6) Take off the transmission jack.
7) Tighten the bolts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
8) Lower the lift.
9) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
case.
NOTE:
When removing ST, be careful not to drop it into
torque converter clutch case.
ST 498277200 STOPPER SET
(2) Install the starter.
<Ref. to SC(H4SO)-6, INSTALLATION, Start-
er.>AT-00103
ST
AT-00109
AT-00026
T2T2
T1
AT-00108

4AT-44
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(3) Tighten the bolts which hold right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
10) Install the torque converter clutch assembly to
drive plate.
(1) Tighten the bolts which hold torque convert-
er clutch assembly to drive plate.
(2) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Fit the plug to the service hole.
11) Remove the ST.12) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
13) Lift-up the vehicle.
14) Replace the snap ring of front drive shaft with a
new one.
15) Apply grease to the oil seal lips.
16) Install ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
17) Align the serration of front differential shaft to
that of differential bevel gear for insertion, and re-
move them using ST.
ST 28399SA010 OIL SEAL PROTECTOR
18) Insert the front drive shaft into transmission se-
curely by pressing the front housing.
19) Install the ball joint onto front housing.
AT-00106
AT-00102
AT-00105
ST
AT-00025
T1
T2
AT-00110ST
AT-00111

4AT-45
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Tighten the attachment bolts.
Tightening torque:
49 N
⋅m (5.0 kgf-m, 36 ft-lb)
21) Install the stabilizer link from the transverse
link.
Tightening torque:
45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
22) Install the shift select cable onto select lever.
<Ref. to CS-13, INSTALLATION, Select Cable.>
23) Connect the ATF cooler hoses to the pipe. (with
ATF cooler (with warmer function))
24) Install the ATF level gauge guide.
25) Install the propeller shaft.
<Ref. to DS-16, INSTALLATION, Propeller Shaft.>
26) Install the heat shield cover. (If equipped)27) Install the rear exhaust pipe and muffler as-
sembly.
(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
Exhaust Pipe.> <Ref. to EX(H4DOTC)-16, IN-
STALLATION, Muffler.>
28) Install the front and center exhaust pipe. (Non-
turbo model)
<Ref. to EX(H4SO)-8, INSTALLATION, Front Ex-
haust Pipe.>
29) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(H4DOTC)-10, INSTALLATION, Center
Exhaust Pipe.>
30) Install the under cover.
31) Lower the lift.
32) Install the ATF cooler assembly bracket to
transmission body. (with ATF cooler (with warmer
function))
NOTE:
Insert the end of ATF cooler bracket to the hole of
converter case.
Tightening torque:
T1: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)
T2: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)
T3: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
AT-00115
AT-00107
AT-00450
AT-01869
T2
T1T3

4AT-46
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
33) Connect the ATF cooler hoses to pipes on
transmission side, and then install the oil charge
pipe. (with ATF cooler (with warmer function))
34) Install the ATF level gauge guide.
35) Connect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
36) Install the harness to bracket.
37) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)38) Install the air cleaner case and air intake duct.
(Non-turbo model).
<Ref. to IN(H4SO)-6, INSTALLATION, Air Cleaner
Case.> <Ref. to IN(H4SO)-7, INSTALLATION, Air
Intake Duct.>
39) Install the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-11, INSTALLATION, Inter-
cooler.>
40) Connect the battery ground cable to battery.
41) Pour ATF from the oil charge pipe. <Ref. to
4AT-30, Automatic Transmission Fluid.>
42) Check the ATF level. <Ref. to 4AT-30, Auto-
matic Transmission Fluid.>
43) Take off the vehicle from a lift.
44) Check the select lever operation.
<Ref. to 4AT-51, INSPECTION, Inhibitor Switch.>
45) Execute the learning control promotion. (Turbo
model) <Ref. to 4AT(H4DOTC)-17, FACILITATION
OF LEARNING CONTROL, OPERATION, Subaru
Select Monitor.>
46) Perform the road test.
<Ref. to 4AT-32, Road Test.>
(A) Inlet hose
(B) Outlet hose
AT-01866(A)(B)
AT-00693
AT-01867

4AT-47
AUTOMATIC TRANSMISSION
Transmission Mounting System
10.Transmission Mounting Sys-
tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. (Non-turbo mod-
el).
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
3) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-10, REMOVAL, Intercool-
er.>
4) Remove the pitching stopper.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle and support it with study
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model).
<Ref. to EX(H4SO)-7, REMOVAL, Front Exhaust
Pipe.> <Ref. to EX(H4SO)-11, REMOVAL, Rear
Exhaust Pipe.> <Ref. to EX(H4SO)-13, REMOV-
AL, Muffler.>
4) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
<Ref. to EX(H4DOTC)-9, REMOVAL, Center Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-14, REMOV-
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-
16, REMOVAL, Muffler.>
5) Remove the heat shield cover. (If equipped)
6) Set the transmission jack under the transmis-
sion.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.7) Remove the transmission rear crossmember.
8) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
2) Install the air cleaner case. (Non-turbo model).
<Ref. to IN(H4SO)-6, INSTALLATION, Air Cleaner
Case.>
3) Install the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-11, INSTALLATION, Inter-
cooler.>
AT-00023
AT-00024
AT-00025
T1
T2

4AT-48
AUTOMATIC TRANSMISSION
Transmission Mounting System
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Install the rear cushion rubber.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
2) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
3) Remove the transmission jack.
4) Install the heat shield cover. (If equipped)
5) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model).
<Ref. to EX(H4SO)-8, INSTALLATION, Front Ex-
haust Pipe.> <Ref. to EX(H4SO)-11, INSTALLA-
TION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-13,
INSTALLATION, Muffler.>
6) Install the center, rear exhaust pipe and muffler.
(Turbo model)
<Ref. to EX(H4DOTC)-10, INSTALLATION, Center
Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, IN-
STALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-16, INSTALLATION, Muffler.>
C: INSPECTION
Perform the following inspection procedures and
repair or replace the parts if defective.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on rubbers.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
Make sure that the crossmember is not bent or
damaged. Ensure there are no cracks, breakage or
damage on cushion rubbers.
AT-00026
T2T2
T1