differential SUBARU FORESTER 2004 Service Owner's Manual

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

AUTOMATIC TRANSMISSION
4AT
Page
1. General Description ....................................................................................2
2. Automatic Transmission Fluid ...................................................................30
3. Differential Gear Oil...................................................................................31
4. Road Test..................................................................................................32
5. Stall Test ...................................................................................................33
6. Time Lag Test ...........................................................................................35
7. Line Pressure Test ....................................................................................36
8. Transfer Clutch Pressure Test ..................................................................38
9. Automatic Transmission Assembly ...........................................................39
10. Transmission Mounting System ................................................................47
11. Extension Case Oil Seal ...........................................................................49
12. Differential Side Retainer Oil Seal.............................................................50
13. Inhibitor Switch ..........................................................................................51
14. Front Vehicle Speed Sensor .....................................................................55
15. Rear Vehicle Speed Sensor ......................................................................59
16. Torque Converter Turbine Speed Sensor .................................................60
17. Control Valve Body ...................................................................................61
18. Air Bleeding of Control Valve ....................................................................70
19.
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.........................71
20. Transfer Duty Solenoid and Valve Body ...................................................73
21. ATF Filter ..................................................................................................76
22. Transmission Control Module (TCM) ........................................................77
23. Dropping Resistor .....................................................................................78
24. ATF Cooler Pipe and Hose .......................................................................79
25. ATF Cooler (With Warmer Function).........................................................84
26. Air Breather Hose......................................................................................87
27. Oil Charger Pipe........................................................................................88
28. Torque Converter Clutch Assembly ..........................................................89
29. Extension Case .........................................................................................90
30. Transfer Clutch..........................................................................................92
31. Reduction Driven Gear..............................................................................97
32. Reduction Drive Gear................................................................................99
33. Parking Pawl ...........................................................................................101
34. Torque Converter Clutch Case ...............................................................102
35. Oil Pump Housing ...................................................................................105
36. Drive Pinion Shaft Assembly ...................................................................111
37. Front Differential......................................................................................117
38. AT Main Case .........................................................................................123
39. Transmission Control Device ..................................................................142

4AT-4
AUTOMATIC TRANSMISSION
General Description
10.FINAL REDUCTION
Model 2.0 L Turbo Non-turbo, 2.5 L Turbo
Front final reduction gear ratio 4.111 (37/9) 4.444 (40/9)
Lubrication oil
(1) Item (3) API classification
(2) Front differential gear oil (4) SAE viscosity No. and applica-
ble temperature
Front differential oil capacity 1.1 — 1.32 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
MT-00001
(1)
(4) GL-5(3) (2)
( C)( F)-30 -26 -15 15
90
85W
80W
75W -9025 30 -5 0-22-1523328659775

4AT-5
AUTOMATIC TRANSMISSION
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(1) Pitching stopper bracket (11) Torque converter clutch ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) O-ring (12) Differential gear oil
Drain plugT1: 18 (1.8, 13.0)
(3) Differential oil level gaugeT2: 41 (4.2, 30.4)
(4) Stay (13) GasketT3: 44 (4.5, 32.5)
(5) Seal pipe (14) Oil sealT4: 33 (3.4, 24.3)
(6) Oil pump shaft (15) Clip (Turbo model)T5: 21 (2.1, 15.5)
(7) Clip (16) Torque converter clutch caseT6: 23 (2.3, 17.0)
(8) Rubber seal (17) ATF cooler (with warmer function)
(if equipped)
(9) Input shaft
(10) O-ring
AT-01862
T2
T2
T2T2
T3
T1
(8)
(11) (1)
(2)
(3)
(4)
(7)(5)
(6)
(10)(9)
(14)
(16)
(12)
(13)
(15)
T5 T4T6(17)

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-20
AUTOMATIC TRANSMISSION
General Description
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly.
41099AC000 ENGINE SUPPORT
ASSEMBLYUsed for supporting engine.
(1) ENGINE SUPPORT BRACKET
(41099AA010)
(2) ENGINE SUPPORT (41099AA020)
398527700 PULLER ASSY  Used for removing extension case roller bear-
ing.
 Used for removing extension oil seal.
 Used for removing front differential side
retainer bearing outer race.
 Used for removing front differential side
retainer oil seal.
498057300 INSTALLER Used for installing extension oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498277200
(2)(1)
ST41099AC000
ST-398527700
ST-498057300

4AT-21
AUTOMATIC TRANSMISSION
General Description
498077000 REMOVER Used for removing differential taper roller bear-
ing.
499247400 INSTALLER  Used for installing transfer outer snap ring.
 Used with GUIDE (499257300).
499257300 SNAP RING
OUTER GUIDE Used for installing transfer outer snap ring.
 Used with INSTALLER (499247400).
499787000 WRENCH ASSY Used for removing and installing differential side
retainer. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498077000
ST-499247400
ST-499257300
ST-499787000

4AT-22
AUTOMATIC TRANSMISSION
General Description
398437700 DRIFT Used for installing torque converter case oil seal.
398487700 INSTALLER Used for installing front differential taper roller
bearing.
398673600 COMPRESSOR Used for removing and installing clutch spring.
498255400 PLATE Used for measuring backlash of hypoid gear. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398437700
ST-398487700
ST-398673600
ST-498255400

4AT-28
AUTOMATIC TRANSMISSION
General Description
899580100 INSTALLER Used for press-fitting the ball bearing for transfer
clutch.
18675AA000 DIFFERENTIAL OIL
SEAL INSTALLERUsed for installing differential side retainer oil
seal.
398497701 SEAT Used for installing needle bearing.
899524100 PULLER SET  Using the bolt only.
(1) BOLT
 Used with PULLER SET (499737100).
 Used with PULLER (499737000).
(1) Puller
(2) Cap ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899580100
ST18675AA000
ST-398497701
ST-899524100