meter SUBARU FORESTER 2004 Service Repair Manual

4AT-2
AUTOMATIC TRANSMISSION
General Description
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO5. PLANETARY GEAR AND PLATE
Model2.0 L
Non-
turbo2.5 L
Non-
turbo2.0 L
Tu r b o2.5 L
Tu r b o
Ty p eSymmetric, 3 element, single stage, 2 phase
torque converter
Stall torque
ratio2.0 —
2.21.9 —
2.11.85 —
2.152.05 —
2.35
Nominal
diameter246 mm (9.69 in)
Stall speed
(at sea level)2,000 —
2,500
rpm2,100 —
2,600
rpm2,600 —
3,300
rpm2,700 —
3,200
rpm
One-way
clutchSprague type one-way clutch
Type Pracoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Ty p e4-forward, 1-reverse, double-row plan-
etary gears
Multi-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch
(sprague type)1 sets
Gear ratio
1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Rev 2.272
Model2.0 L Non-
turbo2.5 L Non-
turboTu r b o
Tooth num-
ber of front
sun gear33
Front pinion
number of
teeth21
Front inter-
nal gear
number of
teeth75
Tooth num-
ber of rear
sun gear42
Rear pinion
number of
teeth17
Tooth num-
ber of rear
internal gear75
Drive &
driven plate
number of
high clutch45
Drive &
driven plate
number of
low clutch467
Drive &
driven plate
number of
reverse
clutch2
Drive &
driven plate
number of 2-
4 brake34
Drive &
driven plate
number of
low &
reverse
brake467

4AT-29
AUTOMATIC TRANSMISSION
General Description
2. GENERAL TOOL
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical system.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
TOOL NAME REMARKS
Depth gauge Used for measuring transmission end play.
Thickness gauge Used for measuring clearance of clutch, brake and oil pump.
Micro meter Used for measuring thickness of drive pinion.
Spring balance Used for measuring starting torque of drive pinion.
Circuit tester Used for measuring resistance and voltage.
TO RX
® T70Used for removing and installing differential gear oil drain plug.
Push/pull gauge Used for measuring stroke of low & reverse piston.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST24082AA230
ST22771AA030

4AT-70
AUTOMATIC TRANSMISSION
Air Bleeding of Control Valve
18.Air Bleeding of Control Valve
A: PROCEDURE
1) Lift-up the vehicle with shifting the select lever to
“P” range and applying the parking brake.
2) Connect the Subaru Select Monitor to the vehi-
cle.
3) Make sure there is no trouble code using Subaru
Select Monitor.
4) Using Subaru Select Monitor, check that the
ATF temperature is in less than 60°C (140°F).
nostic Procedure.>
5) Power OFF the Subaru Select Monitor.
6) Turn the ignition switch to “OFF”.
7) Shift the select lever to “R” range.
8) Depress the brake pedal fully until the air bleed-
ing is completed.
9) Turn the ignition switch to ON.
10) Shift the select lever to “P” range, and then wait
for more than 3 seconds.
11) Shift the select lever to “R” range, and then wait
for more than 3 seconds.
12) Shift the select lever to “N” range, and then wait
for more than 3 seconds.
13) Shift the select lever to “D” range, and then wait
for more than 3 seconds.
14) Shift the select lever to “N” range, and then wait
for more than 3 seconds.
15) Slightly depress the accelerator pedal fully.
16) Slightly release the accelerator pedal fully.
17) Start the engine.
18) Shift the select lever to “D” range.
19) Turn the Subaru Select Monitor switch to ON.
20) Select {Each System Check} in «Main Menu»
of Subaru Select Monitor.
21) On the «System Selection Menu» display
screen, select the “Transmission”. Air bleeding of
control valve starts on transmission. At this time,
the POWER indicator light in combination meter
blinks at 2 Hz. When the POWER indicator light
does not blink, repeat the procedures from step 4).
22) Air bleeding of control valve is finished when
blinking of POWER indicator light in combination
meter changes from 2 Hz to 0.5 Hz.
NOTE:
When blinking of POWER indicator light changes
from 2 Hz to 4 Hz during air bleeding, repeat the
procedure from step 4).
23) Shift the select lever to “N” range, and then turn
the ignition switch to OFF.
24) Shift the select lever to the “P” range, and then
finish the air bleeding.

4AT(H4SO)-4
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: CHECK
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name
Date of purchase
Date of repair
Trans. model TRANSMISSION VIN
Odometer readingkm/h (miles)
Frequency❏ Continuous ❏ Intermittent ( times a day)
Weather❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy
❏ Others
()
Place❏ High ❏ Suburbs ❏ Inner city ❏ Uphill ❏ Rough road
❏ Others
()
Outdoor temperature❏ Hot ❏ Wa r m ❏ Cool ❏ Cold
Vehicle speedkm/h (MPH)
AT warning light (POWER indicator
light)❏ Continuously lit❏ Not lit
Select lever position❏ P ❏ R ❏ N ❏ D ❏ 3 ❏ 2 ❏ 1
Driving condition❏ Not affected
❏ At racing
❏ While decelerating❏ At starting
❏ While accelerating
❏ While turning (❏ RH/❏
LH)❏ While idling
❏ While cruising
POWER switch❏ ON ❏ OFF
HOLD switch❏ ON ❏ OFF
Symptoms❏ No up-shift
❏ No down-shift
❏ No kick down
❏ Vehicle does not move (❏ Any position ❏ Particular position)
❏ Lock-up malfunction
❏ Noise or vibration
❏ Shift shock or slip
❏ Select lever does not move
❏ Others
()

4AT(H4SO)-5
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
Supplemental Restraint System “Airbag”
The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
 All airbag system wiring harness and con-
nectors are colored yellow. Do not use an elec-
trical test equipment on these circuit.
 Be careful not to damage the airbag system wir-
ing harness when performing diagnostics and ser-
vicing the TCM.
Measurement
When measuring the voltage and resistance of
ECM, TCM or each sensor, use a tapered pin with
diameter of less than 0.64 mm (0.025 in) in order to
avoid poor contact. Do not insert the pin more than
0.65 mm (0.256 in).
B: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V or more
Specific gravity: Above 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
Chassis side
Tightening torque:
13 N
⋅m (1.3 kgf-m, 9.4 ft-lb)
3. ATF LEVEL
Make sure that ATF level is in the specification.
mission Fluid.>
4. FRONT DIFFERENTIAL OIL LEVEL
Make sure that the front differential oil level is in speci-
fication. Gear Oil.>
AT-00412
(A) Level gauge
(B) “HOT” side
(C) Upper level
(D) Lower level
(E) “COLD” side
(A) Upper level
(B) Lower level
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)
AT-00317
(A)
(B)
LF

4AT(H4SO)-6
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
General Description
5. OPERATION OF SHIFT SELECT LEVER
Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
WARNING:
Stop the engine while checking operation of se-
lect lever.
6. POWER SWITCH
Make sure that the POWER indicator light in com-
bination meter comes ON, when turning the POW-
ER switch to ON.
7. HOLD SWITCH
Make sure that the HOLD indicator light in combi-
nation meter comes ON, when turning the HOLD
switch to ON.
AT-00413
P
R
N
D
3
2
1
AT-00319
AT-00320

4AT(H4SO)-16
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Transmission Control Module (TCM) I/O Signal
(1) Transmission control module
(TCM)(17) “P” range indicator light (35) Torque control signal 2
(18) “P” range switch (36) Torque control signal 1
(2) Cruise control module (19) “R” range indicator light (37) Intake manifold pressure signal
(3) ABS control module (20) “R” range switch (38) AT diagnostics signal
(4) Ignition switch (21) “N” range indicator light (39) Engine control module (ECM)
(5) Brake switch (22) “N” range switch (40) ATF temperature sensor
(6) Brake light (23) “D” range indicator light (41) Torque converter turbine speed
sensor
(7) Battery (24) “D” range switch
(8) Combination meter (Speedome-
ter circuit)(25) “3” range indicator light (42) Rear vehicle speed sensor
(26) “3” range switch (43) Front vehicle speed sensor
(9) AT OIL TEMP warning light (27) “2” range indicator light (44) Shift solenoid 1
(10) FWD indicator light (28) “2” range switch (45) Shift solenoid 2
(11) POWER indicator light (29) “1” range indicator light (46) 2-4 brake timing solenoid
(12) FWD switch (30) “1” range switch (47) Line pressure duty solenoid
(13) POWER switch (31) Data link connector (48) 2-4 brake duty solenoid
(14) Kick-down switch (32) Throttle position sensor (49) Lock-up duty solenoid
(15) Hold indicator light (33) Engine speed signal (50) Low clutch timing solenoid
(16) HOLD switch (34) Torque control cut signal (51) Transfer duty solenoid

4AT(H4SO)-26
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Power Indicator Light Display
WIRING DIAGRAM:
 LHD model
AT-00570
SBF-4No.14
COMBINATION
METERIGNITION
SWITCH
SBF-1
INHIBITOR SWITCH
E
E
BATTERY
B7
B6
B5
B4
B14
B3
B1
C11
P RND3 2 1
9
8
10
3
11
4
6
53
2
1
8
7
6
5
4
T7
T7B12
B55
B55 B37B56 T3 B12
1234
1234 56
12345656 12345
789
71234567891
0 897 7
8 8
9 9
10 11 12
10 11 10 11
12
13
10 11 12 1312 13
14
1415 14 15
16 16
17 18 17 18
19 20 21 19 20 21
22 23 24 22 23 241234 56 7 8 9
101112
13
1415
1516
1617
1718
1819
1920
2021
2122
2223
2324
24 25 26 27 28 29 30
B:
C:
B9
C2i2B37
POWER
B:
B56 C:TCM
i10 B:i11
1234
5678
9 101112
i10
i11
C:
i3B38
5
6
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
B38
6
C: B:

4AT(H4SO)-27
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Power Indicator Light Display
 RHD model
AT-01823
SBF-4 No.14
COMBINATION
METER SBF-1
INHIBITOR SWITCH
E
E
B7
B6
B5
B4
B14
B3
B1
C11
P RND3 2 1
9
8
10
3
11
4
6
53
2
1
8
7
6
5
4
T7
T7B12
B55
B55
i2B56 T3 B12
12341234
5678
9
10
11
121234 56
123456 56
1234
5 7897
123456
7891089 7
68
79
8 10 1112
10 11
910 12
1310 1112
13
11
121414
15
131416
1517 18
16 192021
17 18192223 24
20 21221234
56789
101112
13
1415
15 16
16 17
17 18
18
1919
2020
2121
2222
2323
2424
2526
2728
29
30
i10
i11
B916
C2i3B38
POWER
B: C:B:
B56 C:
TCM
i10 B:
i11
IGNITION
SWITCH
BATTERY
12
i2B37
i3
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
C:
B:
C:

4AT(H4SO)-28
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Power Indicator Light Display
Step Check Yes No
1 CHECK POWER INDICATOR LIGHT.
Turn the ignition switch to ON (engine OFF).Does the POWER indicator
light illuminate?Go to step 3.Go to step 2.
2 CHECK POWER INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.
3) Remove the POWER indicator light bulb
from combination meter.Is the POWER indicator light
bulb OK?Go to step 4.Replace the
POWER indicator
light bulb.
3 CHECK POWER INDICATOR LIGHT.
Perform “Read Diagnostic Trouble Code
(DTC)”. nostic Trouble Code (DTC).>Does the POWER indicator
light blink?A temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM, inhibitor
switch and combi-
nation meter.Go to step 9.
4 CHECK FUSE (No. 14).
Remove the fuse (No. 14).Is the fuse (No. 14) blown out? Replace the fuse
(No. 14). If
replaced fuse (No.
14) is blown out
easily, repair short
circuit in harness
between fuse (No.
14) and combina-
tion meter.Go to step 5.
5 CHECK HARNESS CONNECTOR BETWEEN
COMBINATION METER AND IGNITION
SWITCH.
1) Turn the ignition switch to ON (engine
OFF).
2) Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i10) No. 9 (+) — Chassis ground (
−):Is the voltage more than 9 V? Go to step 6.Repair the open
circuit in harness
between combina-
tion meter and bat-
tery.
6 CHECK COMBINATION METER.
Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i11) No. 2 (+) — Chassis ground (
−):Is the voltage less than 9 V? Repair the combi-
nation meter.
Combination
Meter Assembly.>Go to step 7.
7 CHECK OPEN CIRCUIT OF HARNESS.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from combination
meter connector.
3) Measure the resistance of harness
between combination meter.
Connector & terminal
(B56) No. 11 — (i11) No. 2:Is the resistance less than 1
Ω?Go to step 8.Repair the open
circuit in harness
between TCM and
combination
meter, and poor
contact in cou-
pling connector.
8 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connector to TCM and combi-
nation meter.
2) Turn the ignition switch to ON (engine
OFF).
3) Measure the voltage between TCM con-
nector and chassis ground.
Connector & terminal
(B56) No. 11 (+) — Chassis ground (
−):Is the voltage less than 1 V? Even if the
POWER indicator
lights up, the cir-
cuit has returned
to a normal condi-
tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM.Replace the TCM.
Transmission Con-
trol Module
(TCM).>