ECU SUBARU FORESTER 2004 Service Repair Manual

4AT-92
AUTOMATIC TRANSMISSION
Transfer Clutch
30.Transfer Clutch
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch assembly. MOVAL, Extension Case.> ASSEMBLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. 95, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
3) Tighten bolts to secure the case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the seal ring.
2) Remove ball bearing using ST and press.
ST 498077600 REMOVER
3) Remove the snap ring, and then take out the
pressure plate, drive plate and driven plate using
flat tip screw driver and etc.
(A) Transfer clutch ASSY
(B) Extension case
AT-00125
(A)
(B)
AT-00118
(A) Seal ring
(B) Rear drive shaft
(A) Snap ring
(B) Rear drive shaft
AT-00127
AT-00128
AT-00129

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-108
AUTOMATIC TRANSMISSION
Oil Pump Housing
4) Install the oil seal retainer and new seal rings.
After installing, adjust the tooth contact and back-
lash of drive pinion. MENT, Oil Pump Housing.>
CAUTION:
There are two kinds of seal rings and those are
identified by color. Be sure to install proper po-
sitions with referring figure.
2. OIL SEAL RETAINER
1) Install two new oil seals to oil seal retainer in
proper direction using ST.
ST 499247300 INSTALLER
2) Install a new O-ring to oil seal retainer using va-
seline.3) Install the oil seal and secure it using three bolts
being careful not to damage oil seal lip.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
E: INSPECTION
1) Check seal ring and oil seal for breaks or dam-
ages.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance
Install the oil pump inner rotor and oil pump out-
er rotor to oil pump. With rotor gears facing each
other, measure crest-to-crest clearance.
Tip clearance:
0.02 — 0.15 mm (0.0008 — 0.0059 in)(A) Seal ring (Black)
(B) Seal ring (Brown)
(A) Oil seal
(B) Oil seal retainer
(A) O-ring
AT-01307
(A)
(B)
AT-00185
(A)
(B)
AT-00186
(A)
(A) Oil seal retainer
(B) Drive pinion shaft
(A) Thickness gauge
(B) Oil pump inner rotor
(C) Oil pump outer rotor
AT-00183
(A)(B)
AT-01038
(B)(C) (A)

4AT-114
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
10) Select three or less shims from following table.
E: INSPECTION
 Make sure that all component parts are free of
harmful cut, gouges, and other faults.
 Adjust the teeth alignment. ADJUSTMENT, Drive Pinion Shaft Assembly.>
F: ADJUSTMENT
1) Remove the liquid gasket completely.
2) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
3) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH4) Adjust backlash between drive pinion and hy-
poid driven gear. MENT, Front Differential.>
5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
pinion in the forward and reverse directions for sev-
eral times. Remove the oil pump housing, and
check the tooth contact pattern.
If the tooth contact is improper, readjust the back-
lash or shim thickness. JUSTMENT, Front Differential.>
 Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
 Face contact
Checking item: Backlash is too large.
Contact pattern
Drive pinion shim
TOOL NUMBER Thickness mm (in)
31451AA050 0.150 (0.0059)
31451AA060 0.175 (0.0069)
31451AA070 0.200 (0.0079)
31451AA080 0.225 (0.0089)
31451AA090 0.250 (0.0098)
31451AA100 0.275 (0.0108)
AT-00205
AT-00206
ST2
ST1
(A) Toe side
(B) Heel side
AT-00207
(A)
(B)
AT-00208

4AT-119
AUTOMATIC TRANSMISSION
Front Differential
2) Secure the case in a vise and remove the hypoid
driven gear tightening bolts, then separate the hy-
poid driven gear, differential case (RH) and differ-
ential case (LH).
3) Pull out the straight pin and pinion shaft, and
then remove the differential bevel gear, washer and
differential bevel pinion.
2. DIFFERENTIAL SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
1) Remove the O-ring.2) Remove the oil seal.
3) Remove the split pin, and then remove the claw.
ST 398527700 PULLER ASSY
4) Attach two claws to the outer race, and set ST to
differential side retainer.
ST 398527700 PULLER ASSY
5) Restore the removed claws to original position,
and install the pin and split pin.
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
(A) Differential case (RH)
(B)
AT-00217
(A)
(C)
AT-00218(A)
AT-00219
(A) Claw
(B) Split pin
(C) Pin
(A) Shaft
(B) Claw
AT-00220
AT-00221
AT-00222

4AT-120
AUTOMATIC TRANSMISSION
Front Differential
6) Hold the shaft of ST to avoid removing from dif-
ferential side retainer, and then remove the bearing
outer race.
ST 398527700 PULLER ASSY
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install the straight pin in reverse direction.
3) Install the washer and differential bevel gear to
differential case (LH). Put the differential case (RH)
on the case, and then combine the both cases.4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 N
⋅m (6.3 kgf-m, 45.6 ft-lb)
5) Measurement of backlash (Selection of washer)
(1) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
 Measure the backlash by applying a differential
pinion tooth between two differential bevel gear
teeth.
 Fix the differential bevel pinion gear in place with
a screwdriver or similar tool when measuring.
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
(2) If the backlash is not within specifications,
select a washer from the table below.
(A) Shaft
(B) Differential side retainer
(A) Differential case (RH)
AT-00223
AT-00218(A)
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
Washer
TOOL NUMBER Thickness mm (in)
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
(B)
AT-00217
(A)
(C)
AT-00224
ST2
ST1

4AT-121
AUTOMATIC TRANSMISSION
Front Differential
6) Using ST, install the taper roller bearing.
ST 398487700 INSTALLER
2. DIFFERENTIAL SIDE RETAINER
1) Install the bearing outer race to differential side
retainer.
2) Install a new oil seal using ST and plastic ham-
mer.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
3) Install a new O-ring.
E: INSPECTION
 Check each component for harmful cuts, dam-
age and other faults.
 Measure the backlash, and then adjust it within
specification.
tial.>
F: ADJUSTMENT
1) Using ST, screw-in the differential side retainer
until light contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
2) Remove the oil pump housing.
3) Remove the liquid gasket completely.
4) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
(A) Taper roller bearing
AT-00225
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
AT-00206
ST2
ST1

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-127
AUTOMATIC TRANSMISSION
AT Main Case
NOTE:
If three points, measure the height every 120°. If
four points, measure the height every 90°.
14) Installation of the low & reverse brake:
Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
NOTE:
Pay attention to the orientation of dish plate.15) Apply compressed air intermittently to check for
operation.
16) Measure the clearance.
Place the same thickness of shim on both sides to
prevent pressure plate from tilting, and then mea-
sure the clearance B and note it.
(A) Dish plate
(B) Driven plate
(C) Drive plate
(D) Retaining plate
(A) Snap ring
AT-01721
(B)
(D)
(C)
(A)
A
AT-00294
(A)
AT-00297
AT-01722
B