SUBARU FORESTER 2004 Service Repair Manual

4AT-58
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
4) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
5) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
6) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
7) Install the front vehicle speed sensor, rear vehi-
cle speed sensor and torque converter turbine
speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)8) Install the ATF cooler inlet and outlet pipes.
NOTE:
Use a new copper 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)
9) Install the transmission rear crossmember bolt.
Tightening torque:
70 N
⋅m (7.1 kgf-m, 51 ft-lb)
10) Install the propeller shaft.

11) Install the heat shield cover. (If equipped)
12) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model).
haust Pipe.> TION, Rear Exhaust Pipe.> INSTALLATION, Muffler.>
13) Install the center, rear exhaust pipe and muf-
fler. (Turbo model)
Exhaust Pipe.> STALLATION, Rear Exhaust Pipe.> EX(H4DOTC)-16, INSTALLATION, Muffler.>
14) Lower the vehicle.
15) Install the transmission connector to the stay.
16) Install the pitching stopper. INSTALLATION, Transmission Mounting System.>
17) Install the air cleaner case. (Non-turbo model).
Case.>
18) Install the intercooler. (Turbo model)
cooler.>
AT-00051
AT-00052
AT-00805
T1
T1
T2

4AT-59
AUTOMATIC TRANSMISSION
Rear Vehicle Speed Sensor
15.Rear Vehicle Speed Sensor
A: REMOVAL
1. NON-TURBO MODEL
When removing the rear vehicle speed sensor, re-
fer to “Front Vehicle Speed Sensor”. 55, REMOVAL, Front Vehicle Speed Sensor.>
2. TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Lift-up the vehicle.
4) Disconnect the connector from rear vehicle
speed sensor.
5) Remove the rear vehicle speed sensor.
B: INSTALLATION
1. NON-TURBO MODEL
When installing the rear vehicle speed sensor, refer
to “Front Vehicle Speed Sensor”. INSTALLATION, Front Vehicle Speed Sensor.>
2. TURBO MODEL
Install in the reverse order of removal.
NOTE:
Replace O-ring with new one.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
(A) Rear vehicle speed sensor
AT-01338
(A)
AT-01341

4AT-60
AUTOMATIC TRANSMISSION
Torque Converter Turbine Speed Sensor
16.Torque Converter Turbine
Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor”.
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor”.
Speed Sensor.>

4AT-61
AUTOMATIC TRANSMISSION
Control Valve Body
17.Control Valve Body
A: REMOVAL
1. NON-TURBO MODEL
1) Lift-up the vehicle.
2) Clean the transmission exterior.
3) Drain the ATF completely.
NOTE:
 Tighten the drain plug (ATF) after draining the
ATF.
 Always use new gasket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Remove the oil pan.
5) Remove and clean the magnet.
6) Remove the old liquid gasket on the oil pan and
transmission case completely.
7) Remove the pipe. (EC, EK model)8) Disconnect the connectors of each solenoid, and
then disconnect the ATF temperature sensor from
control valve.
9) Remove the control valve body.
NOTE:
When removing the control valve body, be careful
not to interfere with transfer duty solenoid wiring.
2. TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Lift-up the vehicle.
4) Clean the transmission exterior.
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)
AT-00801
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
AT-02119
(A) (B) (J) (C) (D) (E)
(I)
(H)
(F) (G)
AT-02120

4AT-62
AUTOMATIC TRANSMISSION
Control Valve Body
5) Remove the drain plug (ATF) and gasket to drain
ATF.
6) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
7) Remove the oil pan.
CAUTION:
Be careful not to entering foreign matter into oil
pan.
8) Remove the magnet.
9) Clean the magnet.
10) Completely remove the remaining liquid gasket
on transmission case and oil pan.11) Remove the control valve connector.
12) Remove the ATF cooler pipe.
13) Remove the control valve body.
NOTE:
Replace the control valve body as assembly, be-
cause it is non-disassemble part.
AT-00055
AT-00056
AT-00057
AT-00058
AT-00059
AT-01717

4AT-63
AUTOMATIC TRANSMISSION
Control Valve Body
B: INSTALLATION
1. NON-TURBO MODEL
1) Set the range select lever in “N” range.
2) Install the control valve, ATF temperature sensor
and ground connectors.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect all connectors.4) Install the pipe. (EC, EK model)
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
5) Attach the magnet at the specified position of oil
pan.
6) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
Bolt length mm (in)
(A) 30 (1.18)
(B) 55 (2.17)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-02121
(A)(A)(A)(A)
(A)(A)
(A)
(A)
(B)
(B)
(B)
(B)
(B)
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
AT-00801
AT-00057
AT-00051

4AT-64
AUTOMATIC TRANSMISSION
Control Valve Body
7) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
8) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
9) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Pour fluid as same amount as drained fluid
from drain plug hole.
10) Inspect the level of ATF.

2. TURBO MODEL
1) Check that the dust and other foreign matters
are not on control valve body.
2) Temporarily assemble the control valve body
and the ground cable to transmission, and install oil
cooler pipe.3) Equally tighten the bolts.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
4) Attach the magnet at the specified position of oil
pan.
5) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
AT-02123
AT-00059
(A) Transmission ground
Bolt length mm (in)
(1) 35 (1.38)
(2) 30 (1.18)
AT-01718
(1)
(1)
(2)
(2)
(2)(2)
(2)
(2)(2)(2)(2)
(2)
(2)
(A)
AT-00057
AT-00051

4AT-65
AUTOMATIC TRANSMISSION
Control Valve Body
6) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
7) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
8) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Pour fluid as same amount as drained fluid
from drain plug hole.
9) Bleed the air of control valve. Air Bleeding of Control Valve.>
10) Check the ATF level. matic Transmission Fluid.>
11) Execute the learning control promotion. to 4AT(H4DOTC)-17, FACILITATION OF LEARN-
ING CONTROL, OPERATION, Subaru Select
Monitor.>
C: DISASSEMBLY
Non-turbo model only
1) Remove the oil strainer from lower control valve
body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
2) Remove the duty solenoids, solenoids and sen-
sor from lower control valve body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
AT-01339
(A) Short bolts
(B) Middle bolt
(C) Long bolts
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-00065
A
ABAA
AC
ACC
AB
AC
CC
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)

4AT-66
AUTOMATIC TRANSMISSION
Control Valve Body
3) Remove the upper and lower control valve body
installing bolt.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
4) Remove the lower control valve body.
5) Remove the oil filter and separate plate.
6) Remove the six steel balls from middle control
valve body.
7) Remove the middle control valve body.8) Remove the upper separator plate from middle
control valve body.
9) Remove the four steel balls and accumulator
spring from upper control valve body.
10) Put the cloth to removing part of piston.
11) Remove the accumulator piston with slowly ap-
ply compressed air to each hole.
12) Remove the seal ring from accumulator piston.
(A) Oil filter
(B) Separate plate
(A) Steel ball
(B) Middle control valve body
AT-02125
B
B
BB D
C
B
D
AA
AA
AT-00068(A)(B)
AT-00069
(A)(B)
(A) Upper separate plate
(B) Side plate
AT-00070
(A)
(B)
AT-00071
AT-00072

4AT-67
AUTOMATIC TRANSMISSION
Control Valve Body
D: ASSEMBLY
1) Install a new seal rings to accumulator piston.
2) Apply ATF to the seal ring.
3) Insert the piston into the back of upper control
valve body.
4) Install the accumulator spring and four steel
balls to specified position of upper control valve
body.5) Align the hole of side plate and hole of upper
separator plate, and then install the side plate and
upper separator plate to middle control valve body.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) Insert the six steel balls to specified position of
middle control valve body.
7) Install the three oil filter to lower valve body.
NOTE:
Pay attention to the oil filter position.
(A) Steel ball
(B) Accumulator spring
AT-00072
AT-00073
AT-00074
(A)
(B)
(A) Upper separate plate
(B) Side plate
(A) Steel ball
(B) Middle control valve body
(A) Oil filter
(B) Lower control valve body
AT-00070
(A)
(B)
AT-00069
(A)(B)
AT-00075
(A)
(B)