lock SUBARU FORESTER 2004 Service Repair Manual

4AT-85
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
B: INSTALLATION
1) Connect the hose to lower side of ATF cooler
(with warmer function), and then install the ATF
cooler (with warmer function) to transmission body.
NOTE:
Insert the tip of ATF cooler bracket into hole of
torque converter case.
Tightening torque:
T1: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)
T2: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)
T3: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
2) Connect the engine coolant inlet hose to cylinder
block and the engine coolant outlet hose to upper
side of engine.3) Connect the hose to pipe on transmission side.
4) Install the harness to bracket.
5) Install the air cleaner case. REMOVAL, Air Cleaner Case.>
6) Fill with engine coolant. REPLACEMENT, Engine Coolant.>
(A) Outlet hose
(B) Inlet hose
AT-01869
T2
T1T3
AT-02113
(A)
(B)
(A) Inlet pipe
(B) Outlet pipe
AT-01866(A)(B)
AT-01867

4AT-95
AUTOMATIC TRANSMISSION
Transfer Clutch
12) Install the transfer clutch assembly without
damaging seal ring.
E: INSPECTION
 Inspect the drive plate facing for wear and dam-
age.
 Inspect the snap ring for wear; return spring for
permanent distortion, breakage and deformation.
 Inspect the damage for D-ring.
 Measure the extension end play and adjust it to
within specifications. MENT, Transfer Clutch.>
1) Check clearance between snap ring and pres-
sure plate.
2) Before measuring clearance, place the same
thickness of shim on both sides to prevent pressure
plate from tilting.
3) If the clearance is out of specification, select a
suitable retaining plate and adjust it.
Standard value:
0.7 — 1.1 mm (0.028 — 0.043 in)
Service limit:
1.6 mm (0.063 in)4) Check that the tight corner braking does not oc-
cur when the vehicle is started with steering wheel
held at fully turned position. If tight corner braking
occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceler-
ation and braking intermittently.
(2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
F: ADJUSTMENT
1) Measure distance “A” from end of extension
case and rear drive shaft with ST.
ST 398643600 GAUGE
2) Measure the distance “B” from the transmission
case end to reduction drive gear end surface with
ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE(A) Transfer clutch ASSY
(B) Extension case
Retaining plate
TOOL NUMBER Thickness mm (in)
31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
AT-00125
(A)
(B)
AT-00142
AST
AT-01029
ST2ST1
B
AT-01030

4AT-97
AUTOMATIC TRANSMISSION
Reduction Driven Gear
31.Reduction Driven Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. Case.>
3) Set the range select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.
5) Using the ST1 and ST2, extract the reduction
driven gear assembly.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
B: INSTALLATION
1) Set the range select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new lock nut.
Tightening torque:
100 N
⋅m (10.2 kgf-m, 73.8 ft-lb)
3) After tightening, stake the lock nut securely.
4) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor. sion Case.>
5) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
(A) Reduction driven gear
(B) Reduction drive gear
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
AT-00153
(A) (B)
AT-00154
(A) (B)
ST1
ST2
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
(A) Snap ring
AT-00153
(A) (B)
AT-00156
(A)

4AT-105
AUTOMATIC TRANSMISSION
Oil Pump Housing
35.Oil Pump Housing
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) 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 part. MOVAL, Torque Converter Clutch Case.>
9) Separate the transmission case and extension
case part. Case.>
10) Remove the reduction drive gear. 99, REMOVAL, Reduction Drive Gear.>
11) Remove the reduction driven gear. 4AT-97, REMOVAL, Reduction Driven Gear.>
12) Loosen the oil pump housing mounting bolts.13) Place two wooden blocks on the workbench,
and stand the transmission case with its rear end
facing down.
CAUTION:
Be careful not to scratch the rear mating sur-
face of transmission case.
NOTE:
Check the height of wooden blocks to avoid dam-
aging the protrudes that on the mating surface of
parking rod and drive pinion.
14) Remove the oil pump housing and adjusting
thrust washer.
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 N
⋅m (4.3 kgf-m, 31 ft-lb)
AT-00114
AT-01034
(A) Oil pump housing
(A) Oil pump housing
AT-00181
(2.17in)55mm
AT-00182
(A)
AT-01035
(A)

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-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)

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-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-140
AUTOMATIC TRANSMISSION
AT Main Case
19) Install the needle bearing, and then secure with
the snap ring.
20) Install the one-way clutch and one-way clutch
inner race, and then secure with the snap ring.
21) Set the one way clutch inner race to D clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
3. 2-4 BRAKE
1) Install 2-4 brake piston to 2-4 brake piston re-
tainer.
4. ONE-WAY CLUTCH INNER RACE
1) Install the needle bearing to inner race using ST
and press.
ST 398497701 SEAT
2) Apply vaseline to the groove of inner race and
new seal ring.
3) Install two seal rings to one-way clutch inner
race.
5. ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and then secure with
the snap ring.
2) Install the one-way clutch and one-way clutch in-
ner race, and then secure with the snap ring.
(A) Needle bearing
(B) Snap ring
(A) Locked
(B) Free
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00268
(B)(A)
AT-00282
(B) (A)
AT-00288
(A)(B)
(A) One-way clutch inner race
(B) Seal ring
(A) Needle bearing
(B) Snap ring
ST
AT-00299
AT-00298(B)(A)
AT-00268
(B)(A)