SUBARU FORESTER 2004 Service Repair Manual

4AT-78
AUTOMATIC TRANSMISSION
Dropping Resistor
23.Dropping Resistor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from dropping resis-
tor.
3) Remove the dropping resistor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
(A) Dropping resistor
AT-00041
AT-00313
(A)
(A) Dropping resistor
AT-00313
(A)
Step Check Yes No
1 CHECK RESISTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from dropping
resistor.
3) Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 9 — 15 Ω? Go to step 2.Replace the drop-
ping resistor. <Ref.
to 4AT-78, Drop-
ping Resistor.>
2 CHECK RESISTOR.
Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 3 — No. 4:Is the resistance 9 — 15 Ω? Dropping resistor
is normal.Replace the drop-
ping resistor. <Ref.
to 4AT-78, Drop-
ping Resistor.>

4AT-79
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
24.ATF Cooler Pipe and Hose
A: REMOVAL
1. EXCEPT WITH ATF COOLER MODEL
(WITH WARMER FUNCTION)
1) Set the vehicle on a lift.
2) Remove the battery and washer tank.
3) Lift-up the vehicle.
4) Remove the under cover.
5) Disconnect the ATF cooler hose from radiator.
(Turbo model)
<Ref. to CO(H4SO)-29, TURBO MODEL, REMOV-
AL, Radiator.>
6) Disconnect the ATF cooler hose from radiator.
(Non-turbo model)
NOTE:
 Do not use a screwdriver or other pointed tools.
 When hard to remove the hose, wrap the hose
with cloth to prevent from damaging, and then turn
with pliers and pull out with hand straightly.
7) Disconnect the ATF cooler hoses from pipes.
NOTE:
 Do not use a screwdriver or other pointed tools.
 When hard to remove the hose, wrap the hose
with cloth to prevent from damaging, and then turn
with pliers and pull out with hand straightly.8) Disconnect the ATF cooler pipe from frame.
9) Remove the ATF cooler inlet and outlet pipes.
CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used with retain-
ing screw.
2. WITH ATF COOLER MODEL (WITH
WARMER FUNCTION)
1) Set the vehicle on a lift.
2) Remove the air cleaner case. <Ref. to
IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
AT-00455
AT-00450
(A) ATF cooler inlet pipe
(B) ATF cooler outlet pipe
AT-00456
AT-00806
(A)
(B)

4AT-80
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
3) Remove the inlet and outlet hoses.
4) Disconnect the transmission harness connector
and remove it from the stay.
5) Remove the oil charger pipe. <Ref. to 4AT-88,
REMOVAL, Oil Charger Pipe.>
6) Remove the ATF cooler assembly and away
from the transmission body.
7) Remove the air breather hose. <Ref. to 4AT-87,
REMOVAL, Air Breather Hose.>8) Remove the oil cooler inlet and outlet pipes.
CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used with retain-
ing screw.
(A) Inlet hose
(B) Outlet hose
AT-01866(A)(B)
AT-01868
(A) ATF cooler outlet pipe
(B) ATF cooler inlet pipe
AT-01870
(A)
(B)
(A)(B)

4AT-81
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
B: INSTALLATION
1. EXCEPT WITH ATF COOLER MODEL
(WITH WARMER FUNCTION)
1) Install the ATF oil cooler inlet pipe and outlet
pipe with new washer.
Tightening torque:
T1: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
T2: 45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
2) Install the ATF cooler pipe to frame.3) Connect the ATF cooler hose to pipe on trans-
mission side.
NOTE:
 Install so that the hose is not folded over, exces-
sively bent, or twisted.
 Be careful to insert the hose to the specified po-
sition.
4) Connect the ATF cooler hose to pipe on radiator
side. (Non-turbo model)
NOTE:
 Install so that the hose is not folded over, exces-
sively bent, or twisted.
 Be careful to insert the hose to the specified po-
sition.
5) Connect the ATF cooler hose to pipe on radiator
side. (Turbo model)
<Ref. to CO(H4SO)-32, TURBO MODEL, INSTAL-
LATION, Radiator.>
6) Install the under cover.
7) Install the battery and washer tank.
8) Fill ATF. <Ref. to 4AT-30, Automatic Transmis-
sion Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-00805
T1
T1
T2
AT-00456
AT-00450
AT-00455

4AT-82
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
2. WITH ATF COOLER MODEL (WITH
WARMER FUNCTION)
1) Install the ATF cooler inlet and outlet pipe with
new washer.
Tightening torque:
T1: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
T2: 41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
T3: 45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
T4: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)2) Install the ATF cooler assembly to transmission.
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)
3) Install the oil charger pipe. <Ref. to 4AT-88, IN-
STALLATION, Oil Charger Pipe.>
4) Install the inlet and outlet hoses.
5) Install the inhibitor switch and transmission har-
ness connector to the stay, and connect the har-
ness connector.
6) Install the air breather hose. <Ref. to 4AT-87, IN-
STALLATION, Air Breather Hose.>
7) Install the air cleaner case. <Ref. to IN(H4SO)-6,
INSTALLATION, Air Cleaner Case.>
(A) ATF cooler outlet pipe
(B) ATF cooler inlet pipe
AT-01871
T1
T2
T3
T4T2
(B)
(A)
(A)(B)
(A) Inlet hose
(B) Outlet hose
AT-01869
T2
T1T3
AT-01866(A)(B)

4AT-83
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
C: INSPECTION
Repair or replace any defective hoses, pipes,
clamps, and washers found from the inspection be-
low.
1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes, and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.

4AT-84
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
25.ATF Cooler (With Warmer
Function)
A: REMOVAL
1) Drain engine coolant. <Ref. to CO(H4SO)-19,
REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner case. <Ref. to IN(H4SO)-
6, REMOVAL, Air Cleaner Case.>
3) Remove the harness from bracket.
4) Disconnect the hose from pipe of transmission.
5) Disconnect the engine coolant inlet hose from
cylinder block and the engine coolant outlet hose
from upper side of engine.6) Remove the ATF Cooler (with warmer function)
from transmission body, and then disconnect the
hose located lower of ATF cooler (with warmer
function).
(A) Inlet pipe
(B) Outlet pipe
(A) Outlet hose
(B) Inlet hose
AT-01867
AT-01866(A)(B)
AT-02113
(A)
(B)
AT-01868

4AT-85
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
B: INSTALLATION
1) Connect the hose to lower side of ATF cooler
(with warmer function), and then install the ATF
cooler (with warmer function) to transmission body.
NOTE:
Insert the tip of ATF cooler bracket into hole of
torque 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)
2) Connect the engine coolant inlet hose to cylinder
block and the engine coolant outlet hose to upper
side of engine.3) Connect the hose to pipe on transmission side.
4) Install the harness to bracket.
5) Install the air cleaner case. <Ref. to IN(H4SO)-6,
REMOVAL, Air Cleaner Case.>
6) Fill with engine coolant. <Ref. to CO(H4SO)-19,
REPLACEMENT, Engine Coolant.>
(A) Outlet hose
(B) Inlet hose
AT-01869
T2
T1T3
AT-02113
(A)
(B)
(A) Inlet pipe
(B) Outlet pipe
AT-01866(A)(B)
AT-01867

4AT-86
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
C: DISASSEMBLY
1) Disconnect each connector from ATF cooler
(with warmer function).
2) Remove the ATF cooler (with warmer function)
from bracket.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
When connecting hose, be careful of its direc-
tion.
Tightening torque:
T1: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)T2: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
E: INSPECTION
Check the ATF cooler (with warmer function) for
damage.
(A) ATF Outlet hose
(B) ATF Inlet hose
(C) Engine coolant inlet hose
(D) Engine coolant outlet hose
AT-02114
(A) (B)(C)
(D)
AT-02115
(A) ATF Inlet hose
(B) ATF Outlet hose
(C) Engine coolant outlet hose
(D) Engine coolant inlet hose
(A) ATF Inlet
(B) ATF Outlet
(C) Engine coolant outlet
(D) Engine coolant inlet
(E) Forward
AT-02116
T1
T2
(B)
(D) (C)
(A)
AT-02117
(D)(B)(A)
(C)
(E)

4AT-87
AUTOMATIC TRANSMISSION
Air Breather Hose
26.Air Breather Hose
A: REMOVAL
1) Remove the air cleaner case. (Non-turbo mod-
el).
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
2) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-10, REMOVAL, Intercool-
er.>
3) Disconnect the air breather hose.
 Non-turbo model
 Turbo model
B: INSTALLATION
1) Install the air breather hose.
 Non-turbo model
 Turbo model
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.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
AT-00099
AT-00098
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
AT-00099
AT-00098