SUBARU FORESTER 2004 Service Repair Manual

4AT-97
AUTOMATIC TRANSMISSION
Reduction Driven Gear
31.Reduction Driven Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-90, REMOVAL, Extension
Case.>
3) Set the range select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.
5) Using the ST1 and ST2, extract the reduction
driven gear assembly.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
B: INSTALLATION
1) Set the range select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new lock nut.
Tightening torque:
100 N
⋅m (10.2 kgf-m, 73.8 ft-lb)
3) After tightening, stake the lock nut securely.
4) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor. <Ref. to 4AT-90, INSTALLATION, Exten-
sion Case.>
5) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
(A) Reduction driven gear
(B) Reduction drive gear
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
AT-00153
(A) (B)
AT-00154
(A) (B)
ST1
ST2
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
(A) Snap ring
AT-00153
(A) (B)
AT-00156
(A)

4AT-98
AUTOMATIC TRANSMISSION
Reduction Driven Gear
2) Remove the ball bearing from reduction driven
gear using ST.
ST 498077600 REMOVER
D: ASSEMBLY
1) Install the new ball bearing to reduction driven
gear using press.
2) Install the snap ring to reduction driven gear.
E: INSPECTION
Make sure the ball bearing and gear is not de-
formed or damaged.
(A) Ball bearing
(A) Ball bearing
(A) Snap ring
AT-00157
(A)ST
AT-00158
(A)
AT-00156
(A)

4AT-99
AUTOMATIC TRANSMISSION
Reduction Drive Gear
32.Reduction Drive Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-90, REMOVAL, Extension
Case.>
3) Remove the reduction driven gear. <Ref. to 4AT-
97, REMOVAL, Reduction Driven Gear.>
4) Using ST, extract the reduction drive gear as-
sembly.
ST1 499737100 PULLER SET
ST2 899524100 PULLER SET
B: INSTALLATION
1) Install the reduction drive gear assembly.
NOTE:
Press-fit it to the bottom of bearing shoulder com-
pletely.
2) Install the reduction driven gear. <Ref. to 4AT-
97, INSTALLATION, Reduction Driven Gear.>
3) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor. <Ref. to 4AT-90, INSTALLATION, Exten-
sion Case.>4) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: DISASSEMBLY
1) Take out the seal ring.
2) Remove ball bearing using ST.
ST 498077600 REMOVER
3) Using press, remove the reduction drive gear.
(A) Reduction drive gear ASSY
(A) Reduction drive gear ASSY
AT-00159
(A)
ST2
ST1
AT-00160
(A)
(A) Seal ring
(B) Reduction drive shaft
(A) Ball bearing
(B) Reduction drive gear
(A) Reduction drive gear
AT-00161
(A)
(B)
AT-00162
(A)
(B)ST
AT-00163
(A)

4AT-100
AUTOMATIC TRANSMISSION
Reduction Drive Gear
D: ASSEMBLY
1) Press-fit the reduction drive gear to shaft.
2) Press-fit the new ball bearing into reduction drive
gear.
3) Apply vaseline to outer surface of new seal ring
and shaft groove.
4) Install the seal ring.
E: INSPECTION
 Rotate the bearing by hand, make sure it rotates
smoothly.
 Make sure that each component is free of harm-
ful gouges, cuts or dust.
 Measure the extension end play and adjust it to
specification. <Ref. to 4AT-95, ADJUSTMENT,
Transfer Clutch.>
(A) Seal ring
(B) Reduction drive shaft
AT-00161
(A)
(B)

4AT-101
AUTOMATIC TRANSMISSION
Parking Pawl
33.Parking Pawl
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-90, REMOVAL, Extension
Case.>
3) Remove the reduction drive gear. <Ref. to 4AT-
99, REMOVAL, Reduction Drive Gear.>
4) Remove the parking pawl, return spring and
shaft.
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
2) Install the reduction drive gear. <Ref. to 4AT-99,
INSTALLATION, Reduction Drive Gear.>
3) Install the extension case and rear vehicle speed
sensor. <Ref. to 4AT-90, INSTALLATION, Exten-
sion Case.>
4) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: INSPECTION
Make sure that the tab of parking pawl on reduction
gear is not worn or otherwise damaged.
(A) Return spring
(B) Parking pawl
(A) Return spring
(B) Parking pawl
AT-00171
(B)(A)
AT-00171
(B)(A)

4AT-102
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
34.Torque Converter Clutch
Case
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.
<Ref. to 4AT-89, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.
4) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
6) Remove the air breather hose. <Ref. to 4AT-87,
REMOVAL, Air Breather Hose.>
7) Remove the ATF charger pipe. <Ref. to 4AT-88,
REMOVAL, Oil Charger Pipe.>
8) Remove the ATF cooler inlet and outlet pipes.
<Ref. to 4AT-79, REMOVAL, ATF Cooler Pipe and
Hose.>9) Remove the torque converter clutch case align-
ing bolt, and then separate the transmission case
and torque converter clutch case by lightly tapping
with plastic hammer.
CAUTION:
 Be careful not to damage the oil seal and
bush inside the torque converter clutch case by
the oil pump cover.
 Do not loosen the rubber seal.
10) Remove the seal pipe.
11) Remove the differential assembly. <Ref. to
4AT-117, REMOVAL, Front Differential.>
12) Remove the oil seal from torque converter
clutch case.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00114
AT-01351
(B)(A)
(A) Seal pipe
AT-00175
AT-00176

4AT-103
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the new oil seal to torque converter
clutch case using ST.
ST 398437700 DRIFT
3) Install the differential assembly to case. <Ref. to
4AT-117, INSTALLATION, Front Differential.>
4) Install the left and right side retainers. <Ref. to
4AT-121, ADJUSTMENT, Front Differential.>
5) Install the new seal pipe to torque converter
clutch case.
6) Install the new rubber seal to torque converter
clutch case.7) Apply proper amount of liquid gasket to the en-
tire matching surface of torque converter clutch
case.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007)
8) Install the torque converter clutch case assem-
bly without damaging bushing and oil seal.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
9) Insert the inhibitor switch connector and trans-
mission connector to the stay.
10) Install the air breather hose. <Ref. to 4AT-87,
INSTALLATION, Air Breather Hose.>
11) Install the ATF cooler pipe. <Ref. to 4AT-81, IN-
STALLATION, ATF Cooler Pipe and Hose.>
12) Install the ATF charger pipe with O-ring. <Ref.
to 4AT-88, INSTALLATION, Oil Charger Pipe.>
(A) Seal pipe
(A) Rubber seal
AT-00177
AT-00176
AT-00178
(A)
(A) THREE BOND 1215
(B) Rubber seal
(B)
(A)
AT-00179
AT-00175

4AT-104
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
13) 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)
14) Install the torque converter clutch assembly.
<Ref. to 4AT-89, INSTALLATION, Torque Convert-
er Clutch Assembly.>
15) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it within
specification. <Ref. to 4AT-114, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
AT-00291
A

4AT-105
AUTOMATIC TRANSMISSION
Oil Pump Housing
35.Oil Pump Housing
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.
<Ref. to 4AT-89, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.
4) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
6) Remove the ATF charger pipe. <Ref. to 4AT-88,
REMOVAL, Oil Charger Pipe.>
7) Remove the ATF cooler inlet and outlet pipes.
<Ref. to 4AT-79, REMOVAL, ATF Cooler Pipe and
Hose.>
8) Separate the torque converter clutch case and
transmission case part. <Ref. to 4AT-102, RE-
MOVAL, Torque Converter Clutch Case.>
9) Separate the transmission case and extension
case part. <Ref. to 4AT-90, REMOVAL, Extension
Case.>
10) Remove the reduction drive gear. <Ref. to 4AT-
99, REMOVAL, Reduction Drive Gear.>
11) Remove the reduction driven gear. <Ref. to
4AT-97, REMOVAL, Reduction Driven Gear.>
12) Loosen the oil pump housing mounting bolts.13) Place two wooden blocks on the workbench,
and stand the transmission case with its rear end
facing down.
CAUTION:
Be careful not to scratch the rear mating sur-
face of transmission case.
NOTE:
Check the height of wooden blocks to avoid dam-
aging the protrudes that on the mating surface of
parking rod and drive pinion.
14) Remove the oil pump housing and adjusting
thrust washer.
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 N
⋅m (4.3 kgf-m, 31 ft-lb)
AT-00114
AT-01034
(A) Oil pump housing
(A) Oil pump housing
AT-00181
(2.17in)55mm
AT-00182
(A)
AT-01035
(A)

4AT-106
AUTOMATIC TRANSMISSION
Oil Pump Housing
2) Install the torque converter clutch case to trans-
mission case. <Ref. to 4AT-89, INSTALLATION,
Torque Converter Clutch Assembly.>
3) Install the reduction driven gear. <Ref. to 4AT-
97, INSTALLATION, Reduction Driven Gear.>
4) Install the reduction drive gear. <Ref. to 4AT-99,
INSTALLATION, Reduction Drive Gear.>
5) Align the transmission case and extension case.
<Ref. to 4AT-90, INSTALLATION, Extension
Case.>
6) Insert the inhibitor switch and transmission con-
nector to the stay.
7) Install the ATF cooler pipe. <Ref. to 4AT-81, IN-
STALLATION, ATF Cooler Pipe and Hose.>
8) Install the ATF charger pipe with O-ring. <Ref. to
4AT-88, INSTALLATION, Oil Charger Pipe.>
9) 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)
10) Install the torque converter clutch assembly.
<Ref. to 4AT-89, INSTALLATION, Torque Convert-
er Clutch Assembly.>
11) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>C: DISASSEMBLY
1. OIL PUMP COVER
1) Remove four seal rings.
2) Remove the installing bolt, and then remove the
cover by lightly tapping the end of starter shaft.
3) Remove the oil pump inner and outer rotor.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A
(A) Seal ring
(A) Oil pump cover
(B) Oil pump housing
(A) Oil pump inner rotor
(B) Oil pump outer rotor
AT-00189
(A)
AT-00190
(A)(B)
AT-01036
(A)(B)