SUBARU FORESTER 2004 Service Repair Manual

4AT-137
AUTOMATIC TRANSMISSION
AT Main Case
3) Install the spring retainer to low clutch piston.
4) Install the ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON
GUIDE
5) Set the cover on the piston with a press using
ST1 and ST2, and attach the snap ring. At this time,
be careful not to fold the cover seal during installa-
tion.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON
GUIDE6) Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
7) Check the low clutch for operation.
(1) Remove the one-way clutch. <Ref. to 4AT-
123, REMOVAL, AT Main Case.>
(2) Set the one-way clutch inner race, and apply
compressed air for checking.
(A) Spring retainer
(B) Low clutch drum
AT-00270
(A)
(B)
AT-00271
ST
AT-00272
ST2
ST3
ST1
(A) Snap ring
(B) Low clutch drum
(C) Dish plate
(D) Low clutch piston side
(A) Apply compressed air.
(B) Low clutch drum
AT-00273
(B)
(A)
(C)
(D)
AT-00274
(B) (A)

4AT-138
AUTOMATIC TRANSMISSION
AT Main Case
8) Check the low clutch clearance.
(1) Place the same thickness of shim on both
sides to prevent pressure plate from tilting.
(2) Check the clearance between retaining
plate and low clutch operation.
Initial standard:
0.7 — 1.1 mm (0.028 — 0.043 in)
Limit thickness:
1.6 mm (0.063 in)
If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ance can be obtained.
9) Install the washer to rear internal gear.10) Install the rear internal gear.
11) Install the thrust needle bearing in correct di-
rection.
12) Install the washer by aligning protrusion of
washer and hole of rear planetary carrier.
(A) Thickness gauge
(B) Low clutch drum
Retaining plate
Tool number Thickness mm (in)
31567AA830 3.8 (0.150)
31567AA840 4.0 (0.157)
31567AA850 4.2 (0.165)
31567AA860 4.4 (0.173)
31567AA870 4.6 (0.181)
(A) Rear internal gear
(B) Washer
AT-00283
(A)
(B)
AT-00275
(A)(B)
(A) Rear internal gear
(B) Low clutch drum
(A) Thrust needle bearing
(B) Low clutch drum
(A) Washer
(B) Rear planetary carrier
AT-00276
(B)
(A)
AT-00277
(B)
(A)
AT-00278
(A)
(B)

4AT-139
AUTOMATIC TRANSMISSION
AT Main Case
13) Install the rear planetary carrier to low clutch
drum.
14) Install the thrust needle bearing in correct di-
rection.
15) Install the rear sun gear in correct direction.16) Install the thrust needle bearing in correct di-
rection.
17) Install the front planetary carrier to low clutch
drum.
18) Install the snap ring to low clutch drum.
(A) Rear planetary carrier
(B) Low clutch drum
(A) Rear sun gear
(B) Rear planetary carrier
AT-00262
(B)
(A)
AT-00279
AT-00261
(B)(A)
(A) Thrust needle bearing
(B) Front planetary carrier
(C) Rear sun gear side
(D) Front planetary carrier side
(A) Front planetary carrier
(B) Low clutch drum
(A) Snap ring
(B) Front planetary carrier
AT-00280
(A)
(B)(C)
(D)
AT-00260
(B) (A)
AT-00281
(B)
(A)

4AT-140
AUTOMATIC TRANSMISSION
AT Main Case
19) Install the needle bearing, and then secure with
the snap ring.
20) Install the one-way clutch and one-way clutch
inner race, and then secure with the snap ring.
21) Set the one way clutch inner race to D clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
3. 2-4 BRAKE
1) Install 2-4 brake piston to 2-4 brake piston re-
tainer.
4. ONE-WAY CLUTCH INNER RACE
1) Install the needle bearing to inner race using ST
and press.
ST 398497701 SEAT
2) Apply vaseline to the groove of inner race and
new seal ring.
3) Install two seal rings to one-way clutch inner
race.
5. ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and then secure with
the snap ring.
2) Install the one-way clutch and one-way clutch in-
ner race, and then secure with the snap ring.
(A) Needle bearing
(B) Snap ring
(A) Locked
(B) Free
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00268
(B)(A)
AT-00282
(B) (A)
AT-00288
(A)(B)
(A) One-way clutch inner race
(B) Seal ring
(A) Needle bearing
(B) Snap ring
ST
AT-00299
AT-00298(B)(A)
AT-00268
(B)(A)

4AT-141
AUTOMATIC TRANSMISSION
AT Main Case
3) Set the one way clutch inner race to low clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
E: INSPECTION
1. HIGH CLUTCH AND REVERSE CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
 Lip seal and D-ring for damage
 Piston and drum check ball for operation
 Adjust total end play. <Ref. to 4AT-109, AD-
JUSTMENT, Oil Pump Housing.>
2. PLANETARY GEAR AND LOW CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
 Lip seal and D-ring for damage
 Piston check ball for operation
 Measure the total end play and adjust it within
specifications. <Ref. to 4AT-109, ADJUSTMENT,
Oil Pump Housing.>
3. 2-4 BRAKE
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
 Lip seal and D-ring for damage
 Measure the total end play and adjust it within
specifications. <Ref. to 4AT-109, ADJUSTMENT,
Oil Pump Housing.>
4. ONE-WAY CLUTCH
 Make sure the snap ring is not worn and the seal
rings are not deformed.
 Measure the total end play and adjust it within
specifications. <Ref. to 4AT-109, ADJUSTMENT,
Oil Pump Housing.>
5. LOW AND REVERSE BRAKE
Check the following:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
(A) Locked
(B) Free
AT-00282
(B) (A)

4AT-142
AUTOMATIC TRANSMISSION
Transmission Control Device
39.Transmission Control Device
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 air breather hose. <Ref. to 4AT-
87, REMOVAL, Air Breather Hose.>
6) Disconnect the inhibitor switch connector from
the stay.
7) Wrap vinyl tape around the nipple attached to
the air breather hose.
8) Remove the pitching stopper bracket.
9) Remove the inhibitor switch.
10) Remove the control valve body assembly.
<Ref. to 4AT-61, REMOVAL, Control Valve Body.>
11) Pull out the spring pin of manual plate.12) Remove the bolts which securing range select
lever, and then remove the range select lever,
manual plate and parking rod.
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
13) Remove the detention spring.
B: INSTALLATION
1) Install the detention spring to transmission case.
Tightening torque:
6 N
⋅m (0.6 kgf-m, 4.4 ft-lb)
AT-00304
AT-00305
(A) Bolt
(B) Range select lever
(C) Manual plate
(D) Parking rod
AT-00306
AT-00307
AT-00307

4AT-143
AUTOMATIC TRANSMISSION
Transmission Control Device
2) Insert the range select lever, and then tighten
the bolt.
Tightening torque:
6 N
⋅m (0.6 kgf-m, 4.4 ft-lb)
3) Insert the manual plate and parking rod.
4) Insert the spring pin to manual plate.
5) Install the oil pan and control valve assembly.
<Ref. to 4AT-63, INSTALLATION, Control Valve
Body.>
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch. <Ref. to
4AT-51, Inhibitor Switch.>9) Insert the inhibitor switch and transmission con-
nector to the stay.
10) Install the air breather hose. <Ref. to 4AT-87,
INSTALLATION, Air Breather Hose.>
11) 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)
12) Install the torque converter clutch assembly.
<Ref. to 4AT-89, INSTALLATION, Torque Convert-
er Clutch Assembly.>
13) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
(A) Bolt
(B) Range select lever
(C) Manual plate
(D) Parking rod
AT-00308
AT-00306
AT-00305
(A) Transmission harness
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A

4AT-144
AUTOMATIC TRANSMISSION
Transmission Control Device

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

AUTOMATIC TRANSMISSION
(DIAGNOSTIC)
4AT(H4SO)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview ...............................................................................4
3. General Description ....................................................................................5
4. Electrical Components Location..................................................................8
5. Transmission Control Module (TCM) I/O Signal .......................................12
6. Subaru Select Monitor...............................................................................17
7. Read Diagnostic Trouble Code (DTC) ......................................................20
8. Inspection Mode ........................................................................................22
9. Clear Memory Mode..................................................................................23
10. Power Indicator Light Display....................................................................24
11. Diagnostic Procedure for Subaru Select Monitor Communication ............32
12. List of Diagnostic Trouble Code (DTC) .....................................................35
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................36
14. Diagnostic Procedure without Diagnostic Trouble Code (DTC) ................84
15. Symptom Related Diagnostic ..................................................................110