clock SUBARU FORESTER 2004 Service Owner's Manual

ME(H4DOTC)-79
MECHANICAL
Cylinder Head Assembly
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.ST 18251AA020 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder head, and insert ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 18251AA020 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
15.8 — 16.2 mm (0.622 — 0.638 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise.
(8) After reaming, clean the valve guide to re-
move chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to ST when reaming.
NOTE:
 If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
 If the inner surface of the valve guide becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ME-00128
ST1
ST2ME-00757
ST
L
ME-00130
ST1
ST2

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-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)

4AT-141
AUTOMATIC TRANSMISSION
AT Main Case
3) Set the one way clutch inner race to low 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.
E: INSPECTION
1. HIGH CLUTCH AND REVERSE CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
 Lip seal and D-ring for damage
 Piston and drum check ball for operation
 Adjust total end play. JUSTMENT, Oil Pump Housing.>
2. PLANETARY GEAR AND LOW CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
 Lip seal and D-ring for damage
 Piston check ball for operation
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
3. 2-4 BRAKE
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
 Lip seal and D-ring for damage
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
4. ONE-WAY CLUTCH
 Make sure the snap ring is not worn and the seal
rings are not deformed.
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
5. LOW AND REVERSE BRAKE
Check the following:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
(A) Locked
(B) Free
AT-00282
(B) (A)

5MT-100
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
 The hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
 The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
 There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
 The differential case has worn or damaged slid-
ing surfaces.
1. DIFFERENTIAL BEVEL PINION GEAR
BACKLASH
Measure the backlash between differential bevel
gear and pinion. If it is not within specifications, in-
stall a suitable washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
2) Install the axle shaft (SUBARU Genuine Parts)
to both sides, move it clockwise and counter clock-
wise to contact tooth, and then read the value of
dial gauge runout.
Parts No. 38415AA100 AXEL SHAFT
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) If the backlash is outside specified range, adjust
it by turning the holder in right side case.
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H) (I)
(H)MT-00285
ST1
ST2
MT-00293ST1
ST2ST3

CL-38
CLUTCH SYSTEM
Clutch Pedal
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nut.
4) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.5) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
 Model without cruise control
 Model with cruise control
6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
7) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)
(A) Stopper
(B) Stopper bolt
(A) Clutch switch
(B) Stopper
(C) Clearance
(A) Accelerator pedal
(B) Clevis
(A)
(B)
CL-00131
(A)
(B) (C)
CL-00132
CL-00101
(B)
(A)

CL-40
CLUTCH SYSTEM
Clutch Pedal
6) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
7) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
8) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
9) Move the clevis pin in lateral direction to ensure
it moves smoothly.
10) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
11) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
12) Install the clutch switch. STALLATION, Clutch Switch.>
(A) Stopper bolt
(A) Clutch pedal
(B) Brake pedal
CL-00134
(A)
CL-00085
(A)
(B)