SUBARU FORESTER 2004 Service Repair Manual

4AT-9
AUTOMATIC TRANSMISSION
General Description
4. CONTROL VALVE AND HARNESS ROUTING
A Non-turbo model B Turbo model
(1) Stay (11) Accumulator piston (23) 2-4 brake duty solenoid
(2) Transmission harness ASSY (12) Accumulator spring (24) Line pressure duty solenoid
(3) O-ring (13) Side plate (25) Low clutch timing solenoid
(4) O-ring (14) Upper separate plate (26) Lock-up duty solenoid
(5) Torque converter turbine speed
sensor(15) Middle control valve body (27) Oil strainer
(16) Separate plate (28) Control valve ASSY
(6) O-ring (17) Fluid filter (29) Rear vehicle speed sensor (turbo
model)
(7) Front vehicle speed sensor (18) Fluid filter
(8) O-ring (19) Lower control valve body
(9) Rear vehicle speed sensor (non-
turbo model)(20) Shift solenoid 2Tightening torque: N
⋅m (kgf-m, ft-lb)
(21) Shift solenoid 1T1: 7 (0.7, 5.1)
(10) Upper control valve body (22) 2-4 brake timing solenoidT2: 8 (0.8, 5.8)
AT-01864
T1T2
T2
T2
T2
T2
T2
T2T2
T2
T1
(1)(2)
(3)(4)
(5)
(6)
(7)
(10)
(11)
(12)
(14)
(13)(15)
(16)
(17)
A(24)(19)
(18)
(20)
(21)
(22)
(23) (26) (25)
(27)
(28)
B
T1
(8)
(9)
T1
(8)
(29)

4AT-10
AUTOMATIC TRANSMISSION
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
(1) High clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Clutch cover (16) Driven plate
(3) D-ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) D-ring (12) Drive plate (19) Snap ring
(6) D-ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
AT-00006

4AT-11
AUTOMATIC TRANSMISSION
General Description
6. PLANETARY GEAR AND 2-4 BRAKE
(1) Thrust needle bearing (10) Washer (19) Snap ring
(2) Front sun gear (11) Thrust needle bearing (20) 2-4 spring retainer
(3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston
(4) Snap ring (13) Washer (22) D-ring
(5) Front planetary carrier (14) Snap ring (23) D-ring
(6) Thrust needle bearing (15) Retaining plate (24) 2-4 brake piston retainer
(7) Rear sun gear (16) Drive plate (25) 2-4 brake seal
(8) Thrust needle bearing (17) Driven plate (26) Leaf spring
(9) Rear planetary carrier (18) Pressure rear plate
AT-00007
(1)(2)(3)(4)(5)
(6)
(14)
(15)
(16)(16)(16)(18)(17)
(20) (26)(17)
(7)
(8)
(9)(10)(11)
(12)(13)
(19)
(21)
(22)
(23)(25)
(24)

4AT-12
AUTOMATIC TRANSMISSION
General Description
7. LOW CLUTCH AND LOW & REVERSE BRAKE
(1) Snap ring (12) Low clutch drum (23) Return spring
(2) Retaining plate (13) Needle bearing (24) Snap ring
(3) Drive plate (14) Snap ring (25) Retaining plate
(4) Driven plate (15) One-way clutch (26) Leaf spring
(5) Dish plate (16) Snap ring (27) Drive plate
(6) Snap ring (17) Thrust needle bearing (28) Driven plate
(7) Cover (18) Seal ring (29) Dish plate
(8) Spring retainer (19) Needle bearing (30) Low & reverse brake piston
(9) D-ring (20) One-way clutch inner race
(10) Low clutch piston (21) Socket boltTightening torque: N
⋅m (kgf-m, ft-lb)
(11) D-ring (22) Spring retainerT: 25 (2.5, 18.1)
AT-01506
(2)(3)(4)(3)(4)(5)(6)(7)(8)(9)(10)(11)
(12)
(17)
(24)(26) (25)(27)(28)(27)(28)(29)(30) (18)(19)(20)(23) (21)
(22)(13)(14)(15)(16)
T
(1)

4AT-13
AUTOMATIC TRANSMISSION
General Description
8. REDUCTION GEAR
(1) Seal ring (6) Snap ringTightening torque: N⋅m (kgf-m, ft-lb)
(2) Ball bearing (7) Ball bearingT: 100 (10.2, 73.8)
(3) Reduction drive gear (8) Reduction driven gear
(4) Reduction drive shaft (9) Washer
(5) Drive pinion shaft (10) Lock nuts
AT-01694
T (2)
(5)(6)(7)(8) (3)(4)
(9) (1)(10)

4AT-14
AUTOMATIC TRANSMISSION
General Description
9. DIFFERENTIAL GEAR
(1) Hypoid driven gear (7) Oil seal (13) Differential bevel gear
(2) Pinion shaft (8) O-ring
(3) Differential case (RH) (9) Differential side retainerTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Straight pin (10) Lock plateT1: 25 (2.5, 18.1)
(5) Differential case (LH) (11) WasherT2: 62 (6.3, 45.6)
(6) Taper roller bearing (12) Differential bevel pinion
AT-00011
T2
T1
T1
(8) (8)
(9) (9)
(7)
(7)(6)
(6)
(10)
(13)
(13) (1)
(2)
(3)
(4)
(5)
(10)(11)
(11)(12) (12)

4AT-15
AUTOMATIC TRANSMISSION
General Description
10.TRANSFER AND EXTENSION CASE
(1) Thrust needle bearing (10) Return spring (20) Dust cover
(2) Needle bearing (11) Transfer clutch piston (21) Test plug
(3) Snap ring (12) Rear drive shaft (22) O-ring
(4) Pressure plate (13) Ball bearing (23) Clip (Turbo model)
(5) Drive plate (14) Seal ring
(6) Driven plate (15) GasketTightening torque: N
⋅m (kgf-m, ft-lb)
(7) Retaining plate (16) Transfer clutch pipeT1: 13 (1.3, 9.4)
(8) Snap ring (17) Extension caseT2: 25 (2.5, 18.1)
(9) Transfer clutch piston
Seal(18) Transmission hanger
(19) Oil seal
AT-00012
(1)(2)(3)(4)(5)(6)(7)
(8)(9)(10)(11)
(16)(23) (18)(19)
(22)(21) (12)(13) (14)
(15)
(5)
(17)
(20)
T2
T2
T1
(6)

4AT-16
AUTOMATIC TRANSMISSION
General Description
11.ATF COOLER (WITH WARMER FUNCTION)
(1) ATF cooler outlet hose (6) Engine coolant outlet hoseTightening torque: N⋅m (kgf-m, ft-lb)
(2) ATF cooler inlet hose (7) ATF cooler bracketT1: 23 (2.3, 17.0)
(3) Hose clamp (8) HoseT2: 33 (3.4, 24.3)
(4) ATF cooler ASSY (9) Clip
(5) Engine coolant inlet hose
AT-01865
T1
(1)
(6)
(4)
(2)
(3)
(5)
(3)(3)
(3)
(3)
(3)
(2)
(3)
(3)
(7) T2
(7)(8)
(10)
(9)

4AT-17
AUTOMATIC TRANSMISSION
General Description
12.TRANSMISSION MOUNTING
(1) Pitching stopper (3) Transmission rear crossmemberTightening torque: N⋅m (kgf-m, ft-lb)
(2) Rear cushion rubber (4) StopperT1: 35 (3.6, 26)
T2: 39 (4.0, 29)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
AT-00014
(2)
(3)
(4) (1)
T4
T3
T5
T5
T2
T2
T1

4AT-18
AUTOMATIC TRANSMISSION
General Description
C: CAUTION
 Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust and dirt.
 Until the oil pan is installed, do not place with the
inside of oil pan facing up to prevent foreign matter
from entering the valve body.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
 Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply gear oil or ATF onto sliding or revolution
surfaces before installation.
 Replace deformed or otherwise damaged snap
rings with new ones.
 Before installing O-rings or oil seals, apply suffi-
cient amount of ATF to avoid damage and defor-
mation.
 Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
 Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
 Avoid damaging the mating surface of the case.
 Before applying sealant, completely remove the
old seal.