lock SUBARU FORESTER 2004 Service Repair Manual

CS-19
CONTROL SYSTEM
MT Gear Shift Lever
6) Connect the stay to transmission bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
7) Install the heat shield cover. (If equipped)
8) Install the rear exhaust pipe and muffler.
 Non-turbo model
haust Pipe.> TION, Muffler.>
 Turbo model
Exhaust Pipe.> STALLATION, Muffler.>
9) Lower the vehicle.
10) Install the plate assembly to body.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
11) Install the drive select cable. INSTALLATION, Drive Select Cable.>12) Install the boot and insulator assembly to the
vehicle in proper direction.
13) Install the clamp.
14) Install the console box. LATION, Console Box.>
C: DISASSEMBLY
1) Remove the lock wire.
2) Remove the rod from gear shift lever.
(A) Stay
(B) Transmission bracket
CS-00050
(A)
(B)
CS-00101
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00100
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)

CS-21
CONTROL SYSTEM
MT Gear Shift Lever
3) Mount each part; boot, O-ring, bushing A, spac-
er, bushing B, bushing and spring pin on the gear
shift lever.
NOTE:
 Always use new O-rings.
 Apply grease [SUNLIGHT 2 (Part No. 003602010)
or equivalent] to the inner and side surfaces of the
bush when installing the spacer.
4) Insert the gear shift lever into boot hole.
5) Install the snap ring and stay to bushing B.6) Tighten with a lock wire to the extent that the
boot will not come off.
NOTE:
Always use new lock wire.
7) Insert the rod into boot hole.
8) Connect the rod to gear shift lever.
Tightening torque:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
(A) Boot
(B) O-ring
(C) Bushing
(D) Spacer
(E) Bushing A
(F) Bushing B
(G) Spring pin
(H) O-ring
(A) Snap ring
(B) Bushing B
CS-00062
(F)(D)(C)
(E)
(G)
(H)
(B)
(A)
CS-00165
(A)(B)
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)

4AT-3
AUTOMATIC TRANSMISSION
General Description
6. SELECTOR POSITION
7. HYDRAULIC CONTROL AND LUBRICA-
TION
8. COOLING AND HARNESS9. TRANSFER
P (Park)Transmission in neutral, output member immov-
able, and engine start possible
R
(Reverse)Transmission in reverse
N (Neu-
tral)Transmission in neutral and engine start possi-
ble
D (Drive)Automatic gear change 1st
←
→ 2nd ←
→ 3rd ←
→
4th
3 (3rd)Automatic gear change 1st
←
→ 2nd ←
→ 3rd ←
4th
2 (2nd)Automatic gear change 1st
←
→ 2nd ← 3rd ←
4th
1 (1st)1st gear locked (Deceleration possible 1st ←
2nd ← 3rd ← 4th)
Control
methodWire cable type
Ty p eElectronic/hydraulic control
[Four forward speed
changes by electrical signals
of vehicle speed and accel-
erator (throttle) opening]
FluidDEXRON III type automatic
transmission fluid
Fluid capac-
ity2.0 L Non-
turbo model8.4 — 8.72 (8.9 — 9.2 US
qt, 7.4 — 7.7 Imp qt)
Except for
2.0 L Non-
turbo model9.3 — 9.62 (9.8 — 10.1 US
qt, 8.2 — 8.4 Imp qt)
Lubrication systemForced feed lubrication with
oil pump
OilAutomatic transmission fluid
(above mentioned)
Cooling SystemLiquid-cooled cooler incorpo-
rated in radiator
Inhibitor switch 12 poles
Transmission harness 20 poles
Model2.0 L Non-
turbo2.5 L Non-
turboTu r b o
Transfer
typeMulti-plate transfer (MPT)
Drive &
driven plate
number of
transfer
clutch456
Control
methodElectronic, hydraulic type
LubricantThe same Automatic transmission fluid used
in automatic transmission
Reduction
gear ratio1.000 (53/53)

4AT-6
AUTOMATIC TRANSMISSION
General Description
2. OIL PUMP
(1) Oil pump rotor (11) Gasket (21) Lock nuts
(2) Oil pump cover (12) O-ring
(3) Seal ring (13) Test plugTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Thrust needle bearing (14) Stud boltT1: 7 (0.7, 5.1)
(5) Drive pinion shaft (15) O-ringT2: 13 (1.3, 9.4)
(6) Roller bearing (16) O-ringT3: 18 (1.8, 13.0)
(7) Drive pinion shim (17) Oil seal retainerT4: 25 (2.5, 18.1)
(8) Oil pump housing (18) Oil sealT5: 40 (4.1, 29.5)
(9) Nipple (19) O-ringT6: 42 (4.3, 31)
(10) Air breather hose (20) Drive pinion collarT7: 116 (11.8, 85)
AT-00003

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-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-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.

4AT-25
AUTOMATIC TRANSMISSION
General Description
499787700 WRENCH Used for removing and installing drive pinion lock
nut.
499787500 ADAPTER Used for removing and installing drive pinion lock
nut.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
498627100 SEAT Used for holding low clutch piston retainer spring
when installing snap ring. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499787700
ST-499787500
ST-398643600
ST-498627100

4AT-27
AUTOMATIC TRANSMISSION
General Description
498937110 HOLDER Used for removing and installing drive pinion lock
nut.
498677100 COMPRESSOR Used for installing 2-4 brake snap ring.
498437000 HIGH CLUTCH PIS-
TO N G UI DEUsed for installing high clutch piston.
498437100 LOW CLUTCH PIS-
TO N G UI DEUsed for installing low clutch piston. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498937110
ST-498677100
ST-498437000
ST-498437100