light SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2356 of 2870
4AT-44
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(3) Tighten the bolts which hold right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
10) Install the torque converter clutch assembly to
drive plate.
(1) Tighten the bolts which hold torque convert-
er clutch assembly to drive plate.
(2) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Fit the plug to the service hole.
11) Remove the ST.12) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
13) Lift-up the vehicle.
14) Replace the snap ring of front drive shaft with a
new one.
15) Apply grease to the oil seal lips.
16) Install ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
17) Align the serration of front differential shaft to
that of differential bevel gear for insertion, and re-
move them using ST.
ST 28399SA010 OIL SEAL PROTECTOR
18) Insert the front drive shaft into transmission se-
curely by pressing the front housing.
19) Install the ball joint onto front housing.
AT-00106
AT-00102
AT-00105
ST
AT-00025
T1
T2
AT-00110ST
AT-00111
Page 2363 of 2870
4AT-50
AUTOMATIC TRANSMISSION
Differential Side Retainer Oil Seal
12.Differential Side Retainer Oil
Seal
A: INSPECTION
Check the leakage of gear oil from differential side
retainer oil seal part.
If there is oil leakage, replace the oil seal.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Remove the front exhaust pipe and center ex-
haust pipe.
(Non-turbo model)
(Turbo model)
3) Drain the differential gear by removing differen-
tial gear oil drain plug.
4) Replace new gasket and tighten the differential
oil drain plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
5) Separate the front drive shaft from transmission.
6) Remove the differential side retainer oil seal us-
ing driver which wrapped with vinyl tape or etc.7) Using ST, install the differential side retainer oil
seal by slightly tapping with hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
8) Apply oil to the oil seal lips.
9) Using the ST, install the front drive shaft.
ST 28399SA010 OIL SEAL PROTECTOR
10) Install the front exhaust pipe and center ex-
haust pipe.
(Non-turbo model)
(Turbo model)
11) Lower the vehicle.
12) Pour differential gear oil into the gauge hole.
Recommended gear oil:
GL-5 (SAE: 75 W-90) or equivalent
Differential gear oil capacity:
1.1 — 1.32 (1.3 — 1.4 US qt, 1.0 — 1.1 Imp qt)
13) Check the gear oil amount.
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)
AT-00029
ST
Page 2364 of 2870
4AT-51
AUTOMATIC TRANSMISSION
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor opera-
tion is erroneous, first check the shift linkage for im-
proper operation. If the shift linkage is functioning
properly, check the inhibitor switch.
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
NOTE:
Also check that continuity in ignition circuit does
not exist when the select lever is in “R”, “D”, “3”, “2”
and “1” ranges.
If the inhibitor switch is inoperative, check for
poor contact of connector on transmission side.3) Check if there is continuity at equal points when
the select lever is turned 1.5° in both directions
from the “N” range to “R” range or “D” range
If there is continuity in one direction and the conti-
nuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch.
4) Repeat the above checks at other ranges. If
there are abnormalities, adjust the select cable.
Signal sent to TCMRange Pin No.
P4 — 3
R4 — 2
N4 — 1
D4 — 8
34 — 7
24 — 6
14 — 5
Ignition circuit P/N 12 — 11
Back-up light circuit R 10 — 9
(A) Inhibitor switch connector
AT-00030
(4)(3)(2) (1)
(5) (6) (7) (8)
(9)
(10) (11) (12)
(A)
(A) Continuity does not exist.
(B) Continuity exists.
(C) 1.5°
(C) (A) (C) (A)
(B)
AT-00452
P
R
N
D
3
2
1
Page 2383 of 2870
4AT-70
AUTOMATIC TRANSMISSION
Air Bleeding of Control Valve
18.Air Bleeding of Control Valve
A: PROCEDURE
1) Lift-up the vehicle with shifting the select lever to
“P” range and applying the parking brake.
2) Connect the Subaru Select Monitor to the vehi-
cle.
3) Make sure there is no trouble code using Subaru
Select Monitor.
4) Using Subaru Select Monitor, check that the
ATF temperature is in less than 60°C (140°F).
5) Power OFF the Subaru Select Monitor.
6) Turn the ignition switch to “OFF”.
7) Shift the select lever to “R” range.
8) Depress the brake pedal fully until the air bleed-
ing is completed.
9) Turn the ignition switch to ON.
10) Shift the select lever to “P” range, and then wait
for more than 3 seconds.
11) Shift the select lever to “R” range, and then wait
for more than 3 seconds.
12) Shift the select lever to “N” range, and then wait
for more than 3 seconds.
13) Shift the select lever to “D” range, and then wait
for more than 3 seconds.
14) Shift the select lever to “N” range, and then wait
for more than 3 seconds.
15) Slightly depress the accelerator pedal fully.
16) Slightly release the accelerator pedal fully.
17) Start the engine.
18) Shift the select lever to “D” range.
19) Turn the Subaru Select Monitor switch to ON.
20) Select {Each System Check} in «Main Menu»
of Subaru Select Monitor.
21) On the «System Selection Menu» display
screen, select the “Transmission”. Air bleeding of
control valve starts on transmission. At this time,
the POWER indicator light in combination meter
blinks at 2 Hz. When the POWER indicator light
does not blink, repeat the procedures from step 4).
22) Air bleeding of control valve is finished when
blinking of POWER indicator light in combination
meter changes from 2 Hz to 0.5 Hz.
NOTE:
When blinking of POWER indicator light changes
from 2 Hz to 4 Hz during air bleeding, repeat the
procedure from step 4).
23) Shift the select lever to “N” range, and then turn
the ignition switch to OFF.
24) Shift the select lever to the “P” range, and then
finish the air bleeding.
Page 2386 of 2870
4AT-73
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
20.Transfer Duty Solenoid and
Valve Body
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the air cleaner case. (Non-turbo mod-
el).
4) Remove the intercooler. (Turbo model)
5) Remove the pitching stopper.
6) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model).
7) Remove the center exhaust pipe. (Turbo model)
8) Remove the rear exhaust pipe and muffler.
(Non-turbo model).
(Turbo model)
10) Remove the heat shield cover. (If equipped)
11) Remove the propeller shaft.
12) Remove the transmission rear crossmember.
(1) Support the transmission using a transmis-
sion jack and raise slightly.
(2) Remove the bolts and nuts as shown in the
figure.
13) Remove the rear vehicle speed sensor.
AT-00023
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential oil drain plug
AT-00016
(A) (B)
(C)
AT-00024
AT-00082
Page 2396 of 2870
4AT-83
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
C: INSPECTION
Repair or replace any defective hoses, pipes,
clamps, and washers found from the inspection be-
low.
1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes, and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
Page 2402 of 2870
4AT-89
AUTOMATIC TRANSMISSION
Torque Converter Clutch Assembly
28.Torque Converter Clutch As-
sembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
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.
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)
Page 2404 of 2870
4AT-91
AUTOMATIC TRANSMISSION
Extension Case
Turbo model
6) Install the transmission assembly.
C: DISASSEMBLY
1) Take out the transfer clutch assembly by lightly
tapping the end of rear drive shaft using plastic
hammer and etc.
NOTE:
Be careful not to damage the oil seal of extension.
2) Remove the transfer clutch pipe without bending
the pipe.
3) Remove the dust cover from extension case.4) Remove the oil seal from the extension case.
D: ASSEMBLY
1) Press-fit new oil seal using ST and press.
ST 498057300 INSTALLER
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to extension case
without bending the pipe.
4) Install the transfer clutch assembly to the case.
NOTE:
Be careful not to damage the seal ring.
Press-fit the transfer clutch assembly to bottom
of bearing shoulder completely.
E: INSPECTION
Use compressed air to make sure the transfer
pipe and extension case routes are not clogged
and not leaks.
Measure the extension end play and adjust it to
within specifications.
(A) Rear vehicle speed sensor
(A) Extension case
(B) Transfer clutch ASSY
(A) Extension case
(B) Transfer clutch pipe
AT-01338
(A)
AT-00119
(A)
(B)
AT-00120
(A)
(B)
(A) Extension case
(B) Transfer clutch pipe
(A) Transfer clutch ASSY
(B) Extension case
AT-00120
(A)
(B)
AT-00125
(A)
(B)
Page 2416 of 2870
4AT-102
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
34.Torque Converter Clutch
Case
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
2) Pull out the torque converter 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 air breather hose.
7) Remove the ATF charger pipe.
8) Remove the ATF cooler inlet and outlet pipes.
ing bolt, and then separate the transmission case
and torque converter clutch case by lightly tapping
with plastic hammer.
CAUTION:
Be careful not to damage the oil seal and
bush inside the torque converter clutch case by
the oil pump cover.
Do not loosen the rubber seal.
10) Remove the seal pipe.
11) Remove the differential assembly.
12) Remove the oil seal from torque converter
clutch case.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00114
AT-01351
(B)(A)
(A) Seal pipe
AT-00175
AT-00176
Page 2418 of 2870
4AT-104
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
13) 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)
14) Install the torque converter clutch assembly.
15) Install the transmission assembly into the vehi-
cle.
C: INSPECTION
Measure the backlash, and then adjust it within
specification.
AT-00291
A