SUBARU FORESTER 2004 Service Repair Manual

4AT-88
AUTOMATIC TRANSMISSION
Oil Charger Pipe
27.Oil Charger Pipe
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) Remove the ATF charger pipe, and then remove
the O-ring from flange side.
 Model without ATF warmer
 Model with ATF warmer
B: INSTALLATION
1) Install the ATF charger pipe with a new O-ring.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
 Model without ATF warmer
 Model with ATF warmer
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 ATF charger pipe is not deformed or
damaged.
(A) ATF level gauge
(B) ATF charger pipe
(A) ATF level gauge
(B) ATF charger pipe
AT-00808
(A)
(B)
AT-01872
(B)
(A)
(A) ATF level gauge
(B) ATF charger pipe
(A) ATF level gauge
(B) ATF charger pipe
AT-00808
(A)
(B)
AT-01872
(B)
(A)

4AT-89
AUTOMATIC TRANSMISSION
Torque Converter Clutch Assembly
28.Torque Converter Clutch As-
sembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Pull out the torque converter clutch assembly
and oil pump shaft horizontally.
CAUTION:
Be sure not to scratch the inside of bush in oil
pump shaft.
3) Remove the input shaft.
NOTE:
When the torque converter clutch assembly is re-
moved, the input shaft is also removed.
4) Remove the clips from torque converter clutch
assembly.
B: INSTALLATION
1) Install the clip to torque converter clutch case.
2) Install the oil pump shaft to torque converter
clutch assembly, and then make sure that the clip is
secured on groove.3) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
4) With holding the torque converter clutch assem-
bly by hands, carefully install to the torque convert-
er clutch case. Take care not to damage the
bushing. Not to contact the oil pump shaft bush and
starter shaft part of oil pump cover inappropriately.
5) Lightly rotating the oil pump shaft by hands to
engage the spline securely, and then check the di-
mension A of torque converter clutch case and
torque converter clutch assembly.
Dimension A:
2.0 L NON-TURBO MODEL
−1.3 — −1.1 mm (−0.015 — −0.043 in)
EXCEPT FOR 2.0 L NON-TURBO MODEL
2.7 — 2.9 mm (0.106 — 0.114 in)
6) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter clutch end is not deformed or damaged.
AT-00113
AT-00114
(A) Dimension A
AT-00291
A
AT-00311
(A)

4AT-90
AUTOMATIC TRANSMISSION
Extension Case
29.Extension Case
A: REMOVAL
1) Remove the transmission assembly.
<Ref. to 4AT-39, REMOVAL, Automatic Transmis-
sion Assembly.>
2) Remove the rear vehicle speed sensor.
 Non-turbo model
 Turbo model
3) Separate the transmission case and extension
case part.
B: INSTALLATION
1) Apply the vaseline to selected thrust needle
bearing and attach it to the end surface of reduction
driven gear. <Ref. to 4AT-95, ADJUSTMENT,
Transfer Clutch.>
NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4) Tighten bolts to secure the extension case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
5) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
 Non-turbo model
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
(A) Rear vehicle speed sensor
AT-00116
(B)
(A)
AT-01338
(A)
AT-00118
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
AT-00118
AT-00116
(B)
(A)

4AT-91
AUTOMATIC TRANSMISSION
Extension Case
 Turbo model
6) Install the transmission assembly.
<Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: DISASSEMBLY
1) Take out the transfer clutch assembly by lightly
tapping the end of rear drive shaft using plastic
hammer and etc.
NOTE:
Be careful not to damage the oil seal of extension.
2) Remove the transfer clutch pipe without bending
the pipe.
3) Remove the dust cover from extension case.4) Remove the oil seal from the extension case.
D: ASSEMBLY
1) Press-fit new oil seal using ST and press.
ST 498057300 INSTALLER
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to extension case
without bending the pipe.
4) Install the transfer clutch assembly to the case.
NOTE:
 Be careful not to damage the seal ring.
 Press-fit the transfer clutch assembly to bottom
of bearing shoulder completely.
E: INSPECTION
 Use compressed air to make sure the transfer
pipe and extension case routes are not clogged
and not leaks.
 Measure the extension end play and adjust it to
within specifications. <Ref. to 4AT-95, ADJUST-
MENT, Transfer Clutch.>
(A) Rear vehicle speed sensor
(A) Extension case
(B) Transfer clutch ASSY
(A) Extension case
(B) Transfer clutch pipe
AT-01338
(A)
AT-00119
(A)
(B)
AT-00120
(A)
(B)
(A) Extension case
(B) Transfer clutch pipe
(A) Transfer clutch ASSY
(B) Extension case
AT-00120
(A)
(B)
AT-00125
(A)
(B)

4AT-92
AUTOMATIC TRANSMISSION
Transfer Clutch
30.Transfer Clutch
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch assembly. <Ref. to 4AT-90, RE-
MOVAL, Extension Case.> <Ref. to 4AT-91, DIS-
ASSEMBLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT-
95, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
3) Tighten bolts to secure the case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: DISASSEMBLY
1) Remove the seal ring.
2) Remove ball bearing using ST and press.
ST 498077600 REMOVER
3) Remove the snap ring, and then take out the
pressure plate, drive plate and driven plate using
flat tip screw driver and etc.
(A) Transfer clutch ASSY
(B) Extension case
AT-00125
(A)
(B)
AT-00118
(A) Seal ring
(B) Rear drive shaft
(A) Snap ring
(B) Rear drive shaft
AT-00127
AT-00128
AT-00129

4AT-93
AUTOMATIC TRANSMISSION
Transfer Clutch
4) Using ST1, ST2 and ST3, remove the snap ring,
and then take out the return spring and transfer
clutch piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
5) Apply compressed air to the rear drive shaft to
remove the transfer clutch piston.
D: ASSEMBLY
1) Install the transfer clutch piston.2) Install the return spring to transfer clutch piston.
3) Install the transfer clutch piston seal.
4) Install ST to the rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
(A) Snap ring
(B) Transfer clutch piston seal
(A) Transfer clutch piston
(B) Rear drive shaft
AT-00130(B) (A)
ST1ST2
ST3
AT-00131
(B)AT-00132
(A)
(A) Return spring
(B) Rear drive shaft
(A) Transfer clutch piston seal
(B) Rear drive shaft
(A) Rear drive shaft
(B)AT-00133
(A)
(B)
AT-00134
(A)
AT-00135
(A)
ST

4AT-94
AUTOMATIC TRANSMISSION
Transfer Clutch
5) Install the snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE
6) Install the snap ring to rear drive shaft using ST1
and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
7) Install the driven plate, drive plate, pressure
plate, retaining plate and snap ring.8) Apply compressed air to see if the assembled
parts move smoothly.
9) Check clearance between snap ring and pres-
sure plate. <Ref. to 4AT-95, INSPECTION, Trans-
fer Clutch.>
10) Press-fit new ball bearing using ST.
ST 899580100 INSTALLER
11) Apply vaseline to seal ring and attach to seal
ring groove of rear drive shaft.
NOTE:
While installing the seal ring, not to expand the seal
ring excessively.
(A) Snap ring
(B) Transfer clutch
(A) Snap ring
(B) Transfer clutch
(A) Snap ring
AT-00136
(A)
(B)ST
AT-00137
(A)
(B)
ST2
ST1
AT-00138
(A)
(A) Ball bearing
(A) Seal ring
(B) Rear drive shaft
AT-00139
AT-00140
(A)
ST
AT-00141
(A)(B)

4AT-95
AUTOMATIC TRANSMISSION
Transfer Clutch
12) Install the transfer clutch assembly without
damaging seal ring.
E: INSPECTION
 Inspect the drive plate facing for wear and dam-
age.
 Inspect the snap ring for wear; return spring for
permanent distortion, breakage and deformation.
 Inspect the damage for D-ring.
 Measure the extension end play and adjust it to
within specifications. <Ref. to 4AT-95, ADJUST-
MENT, Transfer Clutch.>
1) Check clearance between snap ring and pres-
sure plate.
2) Before measuring clearance, place the same
thickness of shim on both sides to prevent pressure
plate from tilting.
3) If the clearance is out of specification, select a
suitable retaining plate and adjust it.
Standard value:
0.7 — 1.1 mm (0.028 — 0.043 in)
Service limit:
1.6 mm (0.063 in)4) Check that the tight corner braking does not oc-
cur when the vehicle is started with steering wheel
held at fully turned position. If tight corner braking
occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceler-
ation and braking intermittently.
(2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
F: ADJUSTMENT
1) Measure distance “A” from end of extension
case and rear drive shaft with ST.
ST 398643600 GAUGE
2) Measure the distance “B” from the transmission
case end to reduction drive gear end surface with
ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE(A) Transfer clutch ASSY
(B) Extension case
Retaining plate
TOOL NUMBER Thickness mm (in)
31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
AT-00125
(A)
(B)
AT-00142
AST
AT-01029
ST2ST1
B
AT-01030

4AT-96
AUTOMATIC TRANSMISSION
Transfer Clutch
3) Calculation formula:
NOTE:
Calculation of “T”:
T = A−B+35.4 mm
[T = A−B+1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end of extension case to end
of rear drive shaft
B: Distance from the end of transmission case to
end of reduction drive gear
Example:
When A = 33.6 mm (1.3228 in), B = 65.05 mm
(2.5610 in)
T = 33.6−65.05+35.4 = 3.95
[T = 1.3228−2.5610+1.3937 = 0.1555]
After calculation, the value of “T” becomes 3.95,
therefore select bearing thickness of 3.8.
NOTE:
Calculation formula for “T” is applied when measur-
ing using ST (398643600 GAUGE, 499577000
GAUGE). When not using ST, apply
T = (A−α+0.45 mm) − (B−β) −H
[T = (A−α+0.0177 in) − (B−β) −H]

T: Thrust needle bearing thickness
A: Distance from the end of extension case to end
of reduction drive shaft
B: Distance from the end of transmission case to
end of rear drive shaft
α: Collar thickness used when measuring “A”
β: Collar thickness used when measuring “B”
0.45: Gasket thickness (mm)
H: Shim clearance
Thrust needle bearing
TOOL NUMBER Thickness mm (in)
806536020 3.8 (0.150)
806535030 4.0 (0.157)
806535040 4.2 (0.165)
806535050 4.4 (0.173)
806535060 4.6 (0.181)
806535070 4.8 (0.189)
806535090 5.0 (0.197)

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
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.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL