SUBARU FORESTER 2004 Service Repair Manual

4AT-117
AUTOMATIC TRANSMISSION
Front Differential
37.Front Differential
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 from the stay.
6) Remove the ATF charger pipe. REMOVAL, Oil Charger Pipe.>
7) Remove the ATF cooler inlet and outlet pipes.
Hose.>
8) Separate the torque converter clutch case and
transmission case. Torque Converter Clutch Case.>
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of torque
converter clutch case.
ST 499787000 WRENCH ASSY
11) Remove the differential assembly without dam-
aging installation part of retainer.
B: INSTALLATION
1) Install the differential assembly to torque con-
verter clutch case.
CAUTION:
Do not damage the inside of torque converter
clutch case (especially the mating surface of
differential side retainer).
2) Install the O-ring to left and right differential side
retainer.
3) Install the side retainers using ST. 117, REMOVAL, Front Differential.>
ST 499787000 WRENCH ASSY
4) Adjust the front differential backlash. 4AT-121, ADJUSTMENT, Front Differential.>
5) Install the lock plate.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
AT-00114(A) Differential ASSY
(A) Lock plate
AT-00215
(A)
AT-00214
(A)

4AT-118
AUTOMATIC TRANSMISSION
Front Differential
6) Install the new seal pipe to torque converter
clutch case.
7) Install the torque converter clutch case to trans-
mission case. Torque Converter Clutch Case.>
8) Insert the inhibitor switch and transmission con-
nector to the stay.
9) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
10) Install the ATF charger pipe with O-ring. to 4AT-88, INSTALLATION, Oil Charger Pipe.>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.
er Clutch Assembly.>
13) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove taper roller bearing using ST and press.
ST 498077000 REMOVER
(A) Seal pipe
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00176
AT-01351
(B)(A)
AT-00291
A
AT-00216

4AT-119
AUTOMATIC TRANSMISSION
Front Differential
2) Secure the case in a vise and remove the hypoid
driven gear tightening bolts, then separate the hy-
poid driven gear, differential case (RH) and differ-
ential case (LH).
3) Pull out the straight pin and pinion shaft, and
then remove the differential bevel gear, washer and
differential bevel pinion.
2. DIFFERENTIAL SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
1) Remove the O-ring.2) Remove the oil seal.
3) Remove the split pin, and then remove the claw.
ST 398527700 PULLER ASSY
4) Attach two claws to the outer race, and set ST to
differential side retainer.
ST 398527700 PULLER ASSY
5) Restore the removed claws to original position,
and install the pin and split pin.
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
(A) Differential case (RH)
(B)
AT-00217
(A)
(C)
AT-00218(A)
AT-00219
(A) Claw
(B) Split pin
(C) Pin
(A) Shaft
(B) Claw
AT-00220
AT-00221
AT-00222

4AT-120
AUTOMATIC TRANSMISSION
Front Differential
6) Hold the shaft of ST to avoid removing from dif-
ferential side retainer, and then remove the bearing
outer race.
ST 398527700 PULLER ASSY
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install the straight pin in reverse direction.
3) Install the washer and differential bevel gear to
differential case (LH). Put the differential case (RH)
on the case, and then combine the both cases.4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 N
⋅m (6.3 kgf-m, 45.6 ft-lb)
5) Measurement of backlash (Selection of washer)
(1) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
 Measure the backlash by applying a differential
pinion tooth between two differential bevel gear
teeth.
 Fix the differential bevel pinion gear in place with
a screwdriver or similar tool when measuring.
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
(2) If the backlash is not within specifications,
select a washer from the table below.
(A) Shaft
(B) Differential side retainer
(A) Differential case (RH)
AT-00223
AT-00218(A)
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
Washer
TOOL NUMBER Thickness mm (in)
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
(B)
AT-00217
(A)
(C)
AT-00224
ST2
ST1

4AT-121
AUTOMATIC TRANSMISSION
Front Differential
6) Using ST, install the taper roller bearing.
ST 398487700 INSTALLER
2. DIFFERENTIAL SIDE RETAINER
1) Install the bearing outer race to differential side
retainer.
2) Install a new oil seal using ST and plastic ham-
mer.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
3) Install a new O-ring.
E: INSPECTION
 Check each component for harmful cuts, dam-
age and other faults.
 Measure the backlash, and then adjust it within
specification.
tial.>
F: ADJUSTMENT
1) Using ST, screw-in the differential side retainer
until light contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
2) Remove the oil pump housing.
3) Remove the liquid gasket completely.
4) 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)
5) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
(A) Taper roller bearing
AT-00225
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
AT-00206
ST2
ST1

4AT-122
AUTOMATIC TRANSMISSION
Front Differential
6) Tighten the LH side of differential side retainer
until contact is felt while rotating the shaft. Then
loosen the RH side of differential side retainer.
Keep tightening the LH side of differential side re-
tainer, and loosening the RH side until the pinion
shaft not be able to turned. This is the “zero” state.
7) After the “zero” state is established, back off the
LH side of differential side retainer 3 notches and
secure it with the lock plate. Then back off the RH
side of differential side retainer and retighten until it
stops. Rotate the drive pinion few times. Tighten
the RH side of differential side retainer 1-3/4 notch-
es further. This sets the preload. Finally, secure the
differential side retainer with its lock plate.
NOTE:
Turning the differential side retainer by one tooth
changes the backlash about 0.05 mm (0.0020 in).8) Turn the drive pinion several times with ST1 and
check to see if the backlash is within the specified
value with ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
9) Adjust the tooth contact between front differen-
tial and drive shaft. MENT, Drive Pinion Shaft Assembly.>
(A) Differential side retainer
(A) Lock plate
AT-00229
(A)
AT-00214
(A)
0.05 mm
(0.0020 in)
AT-00230
AT-00231
ST5
ST3
ST2
ST1
ST4

4AT-123
AUTOMATIC TRANSMISSION
AT Main Case
38.AT Main Case
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.
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. Torque Converter Clutch Case.>
10) Remove the oil pump housing.

11) Take out the high clutch & reverse clutch as-
sembly and thrust needle bearing.12) Take out the high clutch hub and thrust needle
bearing.
13) Take out the front sun gear and thrust needle
bearing.
14) Pull out the leaf spring of 2-4 brake without fold-
ing.
NOTE:
Remove it while pressing down on lower leaf
spring.
(A) High clutch & reverse clutch ASSY
(B) Thrust needle bearing
AT-00114
AT-00232
(B) (A)
(A) High clutch hub
(B) Thrust needle bearing
(A) Front sun gear
(B) Thrust needle bearing
(A) Leaf spring
(B) Retaining plate
AT-00233
(A)
(B)
AT-00251
(A)
(B)
AT-00252
(A)
(B)

4AT-124
AUTOMATIC TRANSMISSION
AT Main Case
15) Remove the snap ring and thrust needle bear-
ing.
16) Take out the retaining plate, drive plate and
driven plate of 2-4 brake.
17) Take out the thrust needle bearing, planetary
gear assembly and low clutch assembly.
18) Remove the 2-4 brake seal.19) Remove the snap ring.
20) Take out the 2-4 brake spring retainer.
21) Remove the 2-4 brake piston and 2-4 brake
piston retainer without damaging.
(A) Snap ring
(B) Thrust needle bearing
AT-00253
(A)(B)
AT-00254
AT-00255
AT-00284
(A) Snap ring
(B) 2-4 brake piston
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00285
(B)
(A)
AT-00286
AT-00287
(A)
(B)

4AT-125
AUTOMATIC TRANSMISSION
AT Main Case
22) Pull out the leaf spring of low & reverse brake
without folding.
23) Remove the snap ring.
24) Take out the retaining plate of low & reverse
brake, drive plate, driven plate and dish plate.
25) Turn the transmission case upside down, and
then take out the socket bolts while holding the
one-way clutch inner race with hand.26) Remove the spring retainer.
27) Take out the return spring.
28) Apply compressed air.
29) Take out the low & reverse brake piston.
(A) Leaf spring
(A) Snap ring
AT-00293
(A)
AT-00294
(A)
AT-00295
AT-00296
AT-00302
AT-00301
AT-00297
AT-00300

4AT-126
AUTOMATIC TRANSMISSION
AT Main Case
B: INSTALLATION
1) Install the low & reverse piston.
CAUTION:
Be careful not to damage the lip seal.
2) Install the return spring.
3) Install the spring retainer.
4) Install the one-way clutch inner race.
5) Tighten the socket head bolts evenly from the
rear side of transmission case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)6) Place the front side of transmission body up.
7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
9) Set the micro gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is
zero point.
10) Scale and record the weight “Z” of a flat board
which will be put on plates.
NOTE:
Use a stiff flat board which does not bend against
load.
Use a flat board of its weight less than 83 N (8.5
kgf, 18.7 lb).
11) Put the flat plate on retaining plate.
12) Using the following formula, calculate “N” indi-
cated on the push/pull gauge
N = 83 N (8.5 kgf, 18.7 lb) − Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate
Z: Flat plate weight
13) Press the center of retaining plate with applying
force of N, and then measure and record the height
A. Make more than three measurements at even
distance and take the average value.
AT-00300
AT-00301
AT-00302
AT-00296
AT-01720