SUBARU FORESTER 2004 Service Repair Manual

4AT-107
AUTOMATIC TRANSMISSION
Oil Pump Housing
2. OIL SEAL RETAINER
1) Remove the oil seal retainer.
2) Remove the O-ring.
3) Remove the oil seal from oil seal retainer.
D: ASSEMBLY
1. OIL PUMP COVER
1) Install the oil pump rotor assembly to oil pump
housing.
2) Align both pivots with the pivot holes of cover,
and then install the oil pump cover being careful not
to apply excessive force to the pivots.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
3) After assembling, turn the oil pump shaft to
check the smooth rotation of rotor.
(A) Oil seal retainer
(B) Drive pinion shaft
(A) O-ring
(A) Oil seal
(B) Oil seal retainer
AT-00183
(A)(B)
AT-00186
(A)
AT-00185
(A)
(B)
(A) Oil pump inner rotor
(B) Oil pump outer rotor
(A) Oil pump cover
(B) Oil pump housing
AT-01036
(A)(B)
AT-00190
(A)(B)

4AT-108
AUTOMATIC TRANSMISSION
Oil Pump Housing
4) Install the oil seal retainer and new seal rings.
After installing, adjust the tooth contact and back-
lash of drive pinion. MENT, Oil Pump Housing.>
CAUTION:
There are two kinds of seal rings and those are
identified by color. Be sure to install proper po-
sitions with referring figure.
2. OIL SEAL RETAINER
1) Install two new oil seals to oil seal retainer in
proper direction using ST.
ST 499247300 INSTALLER
2) Install a new O-ring to oil seal retainer using va-
seline.3) Install the oil seal and secure it using three bolts
being careful not to damage oil seal lip.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
E: INSPECTION
1) Check seal ring and oil seal for breaks or dam-
ages.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance
Install the oil pump inner rotor and oil pump out-
er rotor to oil pump. With rotor gears facing each
other, measure crest-to-crest clearance.
Tip clearance:
0.02 — 0.15 mm (0.0008 — 0.0059 in)(A) Seal ring (Black)
(B) Seal ring (Brown)
(A) Oil seal
(B) Oil seal retainer
(A) O-ring
AT-01307
(A)
(B)
AT-00185
(A)
(B)
AT-00186
(A)
(A) Oil seal retainer
(B) Drive pinion shaft
(A) Thickness gauge
(B) Oil pump inner rotor
(C) Oil pump outer rotor
AT-00183
(A)(B)
AT-01038
(B)(C) (A)

4AT-109
AUTOMATIC TRANSMISSION
Oil Pump Housing
(2) Side clearance
Set depth gauge to oil pump housing, then mea-
sure oil pump housing-to-oil pump rotor clear-
ance.
Side clearance:
0.02 — 0.04 mm (0.0008 — 0.0016 in)
(3) If the depth and/or side clearance are not
within the specifications, replace the oil pump
rotor assembly.
Measure the total end play and adjust it within
specifications. MENT, Oil Pump Housing.>
F: ADJUSTMENT
1) Using ST, measure length “L”, which is from
mating surface of transmission case to concave
side of high clutch drum.
ST 398643600 GAUGE2) Using ST, measure the length from oil pump
housing mating surface to top surface of oil pump
cover with thrust needle bearing.
ST 398643600 GAUGE
3) Calculation of total end play
Select the suitable thrust needle bearing from
among those listed in this table so that clearance C
within 0.25 to 0.55 mm (0.0098 to 0.0217 in).
C = (L+G) −2
(A) DEPTH GAUGE
(B) Oil pump inner rotor
(C) Oil pump outer rotor
Oil pump rotor ASSY
TOOL NUM-
BERThickness mm (in)
15008AA060 11.37 — 11.38 (0.4476 — 0.4480)
15008AA070 11.38 — 11.39 (0.4480 — 0.4484)
15008AA080 11.39 — 11.40 (0.4484 — 0.4488)
AT-01039
(A)
(B)
(C)
AT-00194
L
ST
CClearance between concave portion of high
clutch and end of clutch drum support
LLength from transmission case mating surface
to concave portion of high clutch
G Gasket thickness [0.28 mm (0.0110 in)]
2Height from oil pump housing mating surface to
upper surface of oil pump cover with thrust nee-
dle bearing
Thrust needle bearing
TOOL NUMBER Thickness mm (in)
806528050 4.1 (0.161)
806528060 4.3 (0.169)
806528070 4.5 (0.177)
806528080 4.7 (0.185)
806528090 4.9 (0.193)
806528100 5.1 (0.201)
AT-00195
ST
AT-00196
G
L

4AT-110
AUTOMATIC TRANSMISSION
Oil Pump Housing
4) After completing the end play adjustment, insert
the bearing race in recess of the high clutch. Install
the thrust needle bearing to oil pump cover using
vaseline.
5) After correctly install the new gasket to the case
mating surface, carefully install the oil pump hous-
ing assembly. Be careful to avoid hitting the drive
pinion against the inside of case.
6) Install both parts with dowel pins aligned. Make
sure no clearance at mating surface.

4AT-111
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
36.Drive Pinion Shaft Assembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Pull out the torque converter clutch assembly.
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) Disconnect the air breather hose. 87, REMOVAL, Air Breather Hose.>
7) Remove the ATF charger pipe. REMOVAL, Oil Charger Pipe.>
8) Remove the ATF cooler inlet and outlet pipes.
Hose.>
9) Separate the torque converter clutch case and
transmission case part. MOVAL, Torque Converter Clutch Case.>
10) Separate the transmission case and extension
case part. Case.>
11) Remove the reduction drive gear. 99, REMOVAL, Reduction Drive Gear.>
12) Remove the reduction driven gear. 4AT-97, REMOVAL, Reduction Driven Gear.>13) Remove the drive pinion shaft mounting bolt
and remove the drive shaft assembly from oil pump
housing.
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
housing.
NOTE:
 Be careful not to bend the shim.
 Be careful not to press-fit the pinion into housing
bore.
Tightening torque:
40 N
⋅m (4.1 kgf-m, 29.5 ft-lb)
2) Combine the torque converter case with trans-
mission case. Torque Converter Clutch Case.>
3) Install the reduction driven gear. 97, INSTALLATION, Reduction Driven Gear.>
4) Install the reduction drive gear. INSTALLATION, Reduction Drive Gear.>
5) Align the transmission case and extension case.
Case.>
6) Insert the inhibitor switch and transmission con-
nector to the stay.
7) Install the air breather hose. STALLATION, Air Breather Hose.>
8) Install the ATF cooler inlet and outlet pipes.
and Hose.>
AT-00114
AT-01252
AT-01252

4AT-112
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
9) Install the ATF charger pipe with O-ring.
10) 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)
11) Install the torque converter clutch assembly.
er Clutch Assembly.>
12) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the caulking part of lock nut, and then
remove the lock nut with holding rear spline part of
drive pinion shaft using ST1 and ST2. Pull out the
drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
2) Remove the O-ring.3) Separate the roller bearing and outer race from
drive pinion shaft using the press.
4) Separate the front roller bearing from drive pin-
ion shaft using the press and ST.
ST 498517000 REPLACER
D: ASSEMBLY
1) Measure the dimension “A” of drive pinion shaft
ST 398643600 GAUGE
AT-00291
A
AT-00197
ST1
ST3
ST2
(A) Outer race
(A) Front roller bearing
AT-00198
(A)
AT-00199
(A)
ST
A
AT-00200

4AT-113
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
2) Using a press, press-fit the new roller bearing
into specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
3) After fitting a new O-ring to the drive pinion shaft,
attach the drive pinion collar to the drive pinion
shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten the new lock nuts using ST1, ST2 and
ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/ (L1+L2) ×T1
T1: 116 N⋅m (11.8 kgf-m, 85.3 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTERNOTE:
Install ST2 to torque wrench as straight as possi-
ble.
6) Measure the starting torque of bearing. Make
sure the starting torque is within the specified
range. If the torque is not within specified range, re-
place the roller bearing.
Starting torque:
7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 3.88 kg)
7) Stake the lock nut at two points.
8) Measure the dimension “B” of drive pinion shaft
ST 398643600 GAUGE
9) Calculate the thickness “t” (mm) of drive pinion
shim.
t = 6.5±0.0625− (B−A)
(A) Drive pinion shaft
(B) Roller bearing
Torque wrench length
m (in)Tightening torque
N⋅m (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72.3)
0.45 (17.72) 100 (10.2, 73.5)
0.5 (19.69) 101 (10.3, 74.6)
0.55 (21.65) 102 (10.4, 75.4)
AT-00201
(B)
(A)
ST1
AT-00202
L1 [m (in)]
L2 [m (in)]
ST2
ST3
AT-00203
B
AT-00204

4AT-114
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
10) Select three or less shims from following table.
E: INSPECTION
 Make sure that all component parts are free of
harmful cut, gouges, and other faults.
 Adjust the teeth alignment. ADJUSTMENT, Drive Pinion Shaft Assembly.>
F: ADJUSTMENT
1) Remove the liquid gasket completely.
2) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
3) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH4) Adjust backlash between drive pinion and hy-
poid driven gear. MENT, Front Differential.>
5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
pinion in the forward and reverse directions for sev-
eral times. Remove the oil pump housing, and
check the tooth contact pattern.
If the tooth contact is improper, readjust the back-
lash or shim thickness. JUSTMENT, Front Differential.>
 Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
 Face contact
Checking item: Backlash is too large.
Contact pattern
Drive pinion shim
TOOL NUMBER Thickness mm (in)
31451AA050 0.150 (0.0059)
31451AA060 0.175 (0.0069)
31451AA070 0.200 (0.0079)
31451AA080 0.225 (0.0089)
31451AA090 0.250 (0.0098)
31451AA100 0.275 (0.0108)
AT-00205
AT-00206
ST2
ST1
(A) Toe side
(B) Heel side
AT-00207
(A)
(B)
AT-00208

4AT-115
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft close to hypoid driven gear.
 Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft away from hypoid driven gear.
 Toe contact (inside end contact)
Checking item: Contact areas is small
Contact patternCorrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft away from hypoid driven gear.
 Heel contact (outside end contact)
Checking item: Contact areas is small
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft close to hypoid driven gear.
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212

4AT-116
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
6) If tooth contact is correct, mark the differential
side retainer position and loosen it. After fitting a
new O-ring and oil seal, screw in the differential
side retainer to the marked position. Tighten the
lock plate with specified torque.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(A) Lock plate
AT-00214
(A)