ECU SUBARU FORESTER 2004 Service Repair Manual

CS-18
CONTROL SYSTEM
MT Gear Shift Lever
15) Remove the spring pin, and then extract the
joint.
16) Lower the vehicle.
17) Remove the gear shift lever.
B: INSTALLATION
1) Insert the gear shift lever from room side.
NOTE:
After inserting the rod and stay, temporarily put them
onto transmission mount.
2) Lift-up the vehicle.3) Install the joint to transmission and secure with
the spring pin.
4) Mount the cushion rubber on the body.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
5) Connect the rod to the joint.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) Joint
(B) Spring pin
CS-00053
(A)
(B)
CS-00054
CS-00054
(A) Joint
(B) Spring pin
(A) Stay
(B) Cushion rubber
(A) Stay
(B) Rod
CS-00053
(A)
(B)
CS-00052
(A)
(B)
CS-00051
(A)
(B)

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-40
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
13) Disconnect the hose from lower portion of ATF
cooler (with warmer function), and then secure the
ATF cooler to vehicle using string, etc.
14) Remove the pitching stopper.
15) Separate the torque converter clutch assembly
from drive plate.
(1) Remove the service hole plug.
(2) Remove the bolts which hold torque con-
verter clutch assembly to drive plate.
(3) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
CAUTION:
Be careful not to drop bolts into torque convert-
er clutch housing.16) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
17) Remove the ATF level gauge.
CAUTION:
Plug the opening to prevent entering foreign
particles into transmission fluid.
18) Set ST.
ST 41099AC000 ENGINE SUPPORT ASSEM-
BLY
19) Remove the bolts which hold right upper side of
transmission to engine.
AT-02118
AT-00023
AT-00102
AT-00804
ST
AT-00680
AT-00105
ST
AT-00106

4AT-41
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Lift-up the vehicle.
21) Remove the under cover.
22) Remove the front, center, rear, exhaust pipes
and muffler. (Non-turbo model).
Pipe.> Exhaust Pipe.> AL, Muffler.>
23) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
haust Pipe.> AL, Rear Exhaust Pipe.> 16, REMOVAL, Muffler.>
24) Remove the heat shield cover. (If equipped)
25) Remove the drain plug (ATF) to drain ATF.
26) Disconnect the ATF cooler hoses from pipes of
transmission side, and remove the ATF level gauge
guide. (without ATF cooler (with warmer function))
27) Remove the propeller shaft.

28) Remove the shift select cable.
29) Disconnect the stabilizer link from the trans-
verse link.
30) Remove the bolt securing ball joint of trans-
verse link to housing.
31) Pull out the front drive shaft from transmission.
(1) Face the letter of “AT” to the transmission
side.
ST 28399SA000 DRIVE SHAFT REMOVER
(A) Oil pan
(B) Drain plug (ATF)
AT-00080
(A)(B)
AT-00683
(A) Letter “AT”
AT-00107
AT-00115
AT-00461
(A)

4AT-46
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
33) Connect the ATF cooler hoses to pipes on
transmission side, and then install the oil charge
pipe. (with ATF cooler (with warmer function))
34) Install the ATF level gauge guide.
35) Connect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
36) Install the harness to bracket.
37) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)38) Install the air cleaner case and air intake duct.
(Non-turbo model).
Case.> Intake Duct.>
39) Install the intercooler. (Turbo model)
cooler.>
40) Connect the battery ground cable to battery.
41) Pour ATF from the oil charge pipe. 4AT-30, Automatic Transmission Fluid.>
42) Check the ATF level. matic Transmission Fluid.>
43) Take off the vehicle from a lift.
44) Check the select lever operation.

45) Execute the learning control promotion. (Turbo
model) OF LEARNING CONTROL, OPERATION, Subaru
Select Monitor.>
46) Perform the road test.

(A) Inlet hose
(B) Outlet hose
AT-01866(A)(B)
AT-00693
AT-01867

4AT-57
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
24) Disconnect the ground cable from control valve
connector. (Turbo model)
25) Remove the transmission harness assembly.
B: INSTALLATION
1) Pass the transmission harness assembly
through the hole in the transmission case.2) Connect the harness connectors.
Connect the connectors of same color, and secure
the connectors to valve body using clips. (Non-tur-
bo model)
Tightening torque (Transmission ground ca-
ble):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect the control valve connector, and then
connect the ground cable. (Turbo model)
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
(A) Transmission ground cable
(B) Control valve connector
AT-00050
(B)
(A)
AT-00048
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
(A) Transmission ground cable
(B) Control valve connector
AT-00049
(A) (B) (J) (C) (D) (E)
(I)
(H)
(F) (G)
AT-00050
(B)
(A)

4AT-65
AUTOMATIC TRANSMISSION
Control Valve Body
6) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
7) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
8) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Pour fluid as same amount as drained fluid
from drain plug hole.
9) Bleed the air of control valve. Air Bleeding of Control Valve.>
10) Check the ATF level. matic Transmission Fluid.>
11) Execute the learning control promotion. to 4AT(H4DOTC)-17, FACILITATION OF LEARN-
ING CONTROL, OPERATION, Subaru Select
Monitor.>
C: DISASSEMBLY
Non-turbo model only
1) Remove the oil strainer from lower control valve
body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
2) Remove the duty solenoids, solenoids and sen-
sor from lower control valve body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
AT-01339
(A) Short bolts
(B) Middle bolt
(C) Long bolts
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-00065
A
ABAA
AC
ACC
AB
AC
CC
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)

4AT-74
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
14) Remove the select cable nut.
15) Move the gear select cable so that extension
case securing bolts can be removed.
16) Remove the bolt.
17) Remove the extension case.
NOTE:
Use a container to catch oil flowing from extension.
18) Disconnect the transfer duty solenoid connec-
tor.
19) Remove the transfer duty solenoid and transfer
valve body.B: INSTALLATION
1) Install the transfer duty solenoid and transfer
valve body.
(1) Install the transfer duty solenoid and trans-
fer valve body.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
2) Replace the gasket with a new one, and then in-
stall the extension case to transmission case.
(1) Tighten eleven bolts.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00083
AT-00084
AT-00085
(A)
(C)
(B)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00086
(A)
(C)
(B)
TT
AT-00087
T

4AT-89
AUTOMATIC TRANSMISSION
Torque Converter Clutch Assembly
28.Torque Converter Clutch As-
sembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Pull out the torque converter clutch assembly
and oil pump shaft horizontally.
CAUTION:
Be sure not to scratch the inside of bush in oil
pump shaft.
3) Remove the input shaft.
NOTE:
When the torque converter clutch assembly is re-
moved, the input shaft is also removed.
4) Remove the clips from torque converter clutch
assembly.
B: INSTALLATION
1) Install the clip to torque converter clutch case.
2) Install the oil pump shaft to torque converter
clutch assembly, and then make sure that the clip is
secured on groove.3) 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)
4) With holding the torque converter clutch assem-
bly by hands, carefully install to the torque convert-
er clutch case. Take care not to damage the
bushing. Not to contact the oil pump shaft bush and
starter shaft part of oil pump cover inappropriately.
5) Lightly rotating the oil pump shaft by hands to
engage the spline securely, and then check the di-
mension A of torque converter clutch case and
torque converter clutch assembly.
Dimension A:
2.0 L NON-TURBO MODEL
−1.3 — −1.1 mm (−0.015 — −0.043 in)
EXCEPT FOR 2.0 L NON-TURBO MODEL
2.7 — 2.9 mm (0.106 — 0.114 in)
6) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter clutch end is not deformed or damaged.
AT-00113
AT-00114
(A) Dimension A
AT-00291
A
AT-00311
(A)

4AT-90
AUTOMATIC TRANSMISSION
Extension Case
29.Extension Case
A: REMOVAL
1) Remove the transmission assembly.
sion Assembly.>
2) Remove the rear vehicle speed sensor.
 Non-turbo model
 Turbo model
3) Separate the transmission case and extension
case part.
B: INSTALLATION
1) Apply the vaseline to selected thrust needle
bearing and attach it to the end surface of reduction
driven gear. Transfer Clutch.>
NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4) Tighten bolts to secure the extension case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
5) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
 Non-turbo model
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
(A) Rear vehicle speed sensor
AT-00116
(B)
(A)
AT-01338
(A)
AT-00118
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
AT-00118
AT-00116
(B)
(A)